Apparatus for radially expanding and plastically deforming a tubular member

ABSTRACT

An apparatus for radially expanding and plastically deforming a tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the filing date of U.S.provisional patent application Ser. No. 60/463,586, filed on Apr. 17,2003, the disclosure of which is incorporated herein by reference.

The present application is a continuation-in-part of the following: (1)PCT patent application serial number PCT/US02/36157, filed on Nov. 12,2002, (2) PCT patent application serial number PCT/US02/36267, filed onNov. 12, 2002, (3) PCT patent application serial number PCT/US03/04837,filed on Feb. 29, 2003, (4) PCT patent application serial numberPCT/US03/29859, filed on Sep. 22, 2003, (5) PCT patent applicationserial number PCT/US03/14153, filed on Nov. 13, 2003, (6) PCT patentapplication serial number PCT/US03/18530, filed on Jun. 11, 2003, (7)PCT patent application serial number PCT/US03/29858, PCT patentapplication serial number PCT/US03/29460, filed on Sep. 23, 2003, filedon Sep. 22, 2003, (9) PCT patent application serial numberPCT/US04/07711, filed on Mar. 11, 2004, (10) PCT patent applicationserial number PCT/US04/09434, filed on Mar. 26, 2004, (11) PCT patentapplication serial number PCT/US04/10317, filed on Apr. 2, 2004, (12)PCT patent application serial number PCT/US04/10712, filed on Apr. 7,2004, and (13) PCT patent application serial number PCT/US04/10762,filed on Apr. 6, 2004, the disclosures of which are incorporated hereinby reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, whichclaims priority from provisional application 60/121,702, filed on Feb.25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb.10, 2000, which claims priority from provisional application 60/119,611,filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed asU.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, filed onJul. 1, 2002, which claims priority from provisional application60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S.Pat. No. 6,568,471, which was filed as patent application Ser. No.09/512,895, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S.Pat. No. 6,575,240, which was filed as patent application Ser. No.09/511,941, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, filed on Jun. 7, 2000, which claims priority fromprovisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S.patent application Ser. No. 09/981,916, filed on Oct. 18, 2001 as acontinuation-in-part application of U.S. Pat. No. 6,328,113, which wasfiled as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed asapplication Ser. No. 09/559,122, filed on Apr. 26, 2000, which claimspriority from provisional application 60/131,106, filed on Apr. 26,1999, (12) U.S. patent application Ser. No. 10/030,593, filed on Jan. 8,2002, which claims priority from provisional application 60/146,203,filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser.No. 60/143,039, filed on Jul. 9, 1999, (14) U.S. patent application Ser.No. 10/111,982, filed on Apr. 30, 2002, which claims priority fromprovisional patent application Ser. No. 60/162,671, filed on Nov. 1,1999, (15) U.S. provisional patent application Ser. No. 60/154,047,filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser.No. 60/438,828, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,which was filed as application Ser. No. 09/679,907, on Oct. 5, 2000,which claims priority from provisional patent application Ser. No.60/159,082, filed on Oct. 12, 1999, (18) U.S. patent application Ser.No. 10/089,419, filed on Mar. 27, 2002, which claims priority fromprovisional patent application Ser. No. 60/159,039, filed on Oct. 12,1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5,2000, which claims priority from provisional patent application Ser. No.60/159,033, filed on Oct. 12, 1999, (20) U.S. patent application Ser.No. 10/303,992, filed on Nov. 22, 2002, which claims priority fromprovisional patent application Ser. No. 60/212,359, filed on Jun. 19,2000, (21) U.S. provisional patent application Ser. No. 60/165,228,filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser.No. 60/455,051, filed on Mar. 14, 2003, (23) PCT application US02/2477,filed on Jun. 26, 2002, which claims priority from U.S. provisionalpatent application Ser. No. 60/303,711, filed on Jul. 6, 2001, (24) U.S.patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, whichclaims priority from provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.10/, filedon Dec. 18, 2002, which claims priority from provisional patentapplication Ser. No. 60/221,645, filed on Jul. 28, 2000, (26) U.S.patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, whichclaims priority from provisional patent application Ser. No. 60/233,638,filed on Sep. 18, 2000, (27) U.S. patent application Ser. No.10/406,648, filed on Mar. 31, 2003, which claims priority fromprovisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, whichclaims priority from U.S. provisional patent application Ser. No.60/270,007, filed on Feb. 20, 2001, (29) U.S. patent application Ser.No. 10/465,835, filed on Jun. 13, 2003, which claims priority fromprovisional patent application Ser. No. 60/262,434, filed on Jan. 17,2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun.13, 2003, which claims priority from U.S. provisional patent applicationSer. No. 60/259,486, filed on Jan. 3, 2001, (31) U.S. provisional patentapplication Ser. No. 60/452,303, filed on Mar. 5, 2003, (32) U.S. Pat.No. 6,470,966, which was filed as patent application Ser. No.09/850,093, filed on May 7, 2001, as a divisional application of U.S.Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (33) U.S.Pat. No. 6,561,227, which was filed as patent application Ser. No.09/852,026, filed on May 9, 2001, as a divisional application of U.S.Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (34) U.S.patent application Ser. No. 09/852,027, filed on May 9, 2001, as adivisional application of U.S. Pat. No. 6,497,289, which was filed asU.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed on1217198, (35) PCT Application US02/25608, filed on Aug. 13, 2002, whichclaims priority from provisional application 60/318,021, filed on Sep.7, 2001, (36) PCT Application US02/24399, filed on Aug. 1, 2002, whichclaims priority from U.S. provisional patent application Ser. No.60/313,453, filed on Aug. 20, 2001, (37) PCT Application US02/29856,filed on Sep. 19, 2002, which claims priority from U.S. provisionalpatent application Ser. No. 60/326,886, filed on Oct. 3, 2001, (38) PCTApplication US02/20256, filed on Jun. 26, 2002, which claims priorityfrom U.S. provisional patent application Ser. No. 60/303,740, filed onJul. 6, 2001, (39) U.S. patent application Ser. No. 09/962,469, filed onSep. 25, 2001, which is a divisional of U.S. patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (40) U.S.patent application Ser. No. 09/962,470, filed on Sep. 25, 2001, which isa divisional of U.S. patent application Ser. No. 09/523,468, filed onMar. 10, 2000, which claims priority from provisional application60/124,042, filed on Mar. 11, 1999, (41) U.S. patent application Ser.No. 09/962,471, filed on Sep. 25, 2001, which is a divisional of U.S.patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, whichclaims priority from provisional application 60/124,042, filed on Mar.11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed onSep. 25, 2001, which is a divisional of U.S. patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (43) U.S.patent application Ser. No. 09/962,468, filed on Sep. 25, 2001, which isa divisional of U.S. patent application Ser. No. 09/523,468, filed onMar. 10, 2000, which claims priority from provisional application60/124,042, filed on Mar. 11, 1999, (44) PCT application US 02/25727,filed on Aug. 14, 2002, which claims priority from U.S. provisionalpatent application Ser. No. 60/317,985, filed on Sep. 6, 2001, and U.S.provisional patent application Ser. No. 60/318,386, filed on Sep. 10,2001, (45) PCT application US 02/39425, filed on Dec. 10, 2002, whichclaims priority from U.S. provisional patent application Ser. No.60/343,674, filed on Dec. 27, 2001, (46) U.S. utility patent applicationSer. 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No. 09/512,895,filed on Feb. 24, 2000, which claims priority from provisionalapplication 60/121,841, filed on Feb. 26, 1999, (59) U.S. patentapplication Ser. No. 10/262,009, filed on Oct. 1, 2002, which is adivisional of U.S. Pat. No. 6,557,640, which was filed as patentapplication Ser. No. 09/588,946, filed on Jun. 7, 2000, which claimspriority from provisional application 60/137,998, filed on Jun. 7, 1999,(60) U.S. patent application Ser. No. 10/092,481, filed on Mar. 7, 2002,which is a divisional of U.S. Pat. No. 6,568,471, which was filed aspatent application Ser. No. 09/512,895, filed on Feb. 24, 2000, whichclaims priority from provisional application 60/121,841, filed on Feb.26, 1999, (61) U.S. patent application Ser. No. 10/261,926, filed onOct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, whichwas filed as patent application Ser. No. 09/588,946, filed on Jun. 7,2000, which claims priority from provisional application 60/137,998,filed on Jun. 7, 1999, (62) PCT application US 02/36157, filed on Nov.12, 2002, which claims priority from U.S. provisional patent applicationSer. No. 60/338,996, filed on Nov. 12, 2001, (63) PCT application US02/36267, filed on Nov. 12, 2002, which claims priority from U.S.provisional patent application Ser. No. 60/339,013, filed on Nov. 12,2001, (64) PCT application US 03/11765, filed on Apr. 16, 2003, whichclaims priority from U.S. provisional patent application Ser. No.60/383,917, filed on May 29, 2002, (65) PCT application US 03/15020,filed on May 12, 2003, which claims priority from U.S. provisionalpatent application Ser. No. 60/391,703, filed on Jun. 26, 2002, (66) PCTapplication US 02/39418, filed on Dec. 10, 2002, which claims priorityfrom U.S. provisional patent application Ser. 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No. 10/262,008, filed on Oct. 1, 2002,which is a divisional of U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. No. 09/588,946, filed on Jun. 7, 2000, whichclaims priority from provisional application 60/137,998, filed on Jun.7, 1999, (72) U.S. patent application Ser. No. 10/261,925, filed on Oct.1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which wasfiled as patent application Ser. No. 09/588,946, filed on Jun. 7, 2000,which claims priority from provisional application 60/137,998, filed onJun. 7, 1999, (73) U.S. patent application Ser. No. 10/199,524, filed onJul. 19, 2002, which is a continuation of U.S. Pat. No. 6,497,289, whichwas filed as U.S. patent application Ser. No. 09/454,139, filed on Dec.3, 1999, which claims priority from provisional application 60/111,293,filed on Dec. 7, 1998, (74) PCT application US 03/10144, filed on Mar.28, 2003, which claims priority from U.S. provisional patent applicationSer. 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No. 60/412,653,filed on Sep. 20, 2002, (87) U.S. provisional patent application Ser.No. 60/405,610, filed on Aug. 23, 2002, (88) U.S. provisional patentapplication Ser. No. 60/405,394, filed on Aug. 23, 2002, (89) U.S.provisional patent application Ser. No. 60/412,544, filed on Sep. 20,2002, (90) PCT application US 03/24779, filed on Aug. 8, 2003, whichclaims priority from U.S. provisional patent application Ser. No.60/407,442, filed on Aug. 30, 2002, (91) U.S. provisional patentapplication Ser. No. 60/423,363, filed on Dec. 10, 2002, (92) U.S.provisional patent application Ser. No. 60/412,196, filed on Sep. 20,2002, (93) U.S. provisional patent application Ser. No. 60/412,187,filed on Sep. 20, 2002, (94) U.S. provisional patent application Ser.No. 60/412,371, filed on Sep. 20, 2002, (95) U.S. patent applicationSer. No. 10/382,325, filed on Mar. 5, 2003, which is a continuation ofU.S. Pat. No. 6,557,640, which was filed as patent application Ser. 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PCT/US04/06246, filed on 2/26/2004, (123)PCT patent application serial number PCT/US04/08170, filed on Mar. 15,2004, (124) PCT patent application serial number PCT/US04/08171, filedon Mar. 15, 2004, (125) PCT patent application serial numberPCT/US04/08073, filed on Mar. 18, 2004, (126) PCT patent applicationserial number PCT/US04/07711, filed on Mar. 11, 2004, (127) PCT patentapplication serial number PCT/US04/09434, filed on Mar. 26, 2004, (128)PCT patent application serial number PCT/US04/10317, filed on Apr. 2,2004, (129) PCT patent application serial number PCT/US04/10712, filedon 04/06/2004, and (130) PCT patent application serial numberPCT/US04/10762, filed on 04/06/2004, the disclosures of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member, a cutting device forcutting the tubular member coupled to the support member, and anexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member, an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member, and an actuator coupled to the supportmember for displacing the expansion device relative to the supportmember.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member; and a sealing assembly for sealing anannulus defined between the support member and the tubular member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; a first expansiondevice for radially expanding and plastically deforming the tubularmember coupled to the support member; and a second expansion device forradially expanding and plastically deforming the tubular member coupledto the support member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member; and a packer coupled to the supportmember.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; a cutting device forcutting the tubular member coupled to the support member; a grippingdevice for gripping the tubular member coupled to the support member; asealing device for sealing an interface with the tubular member coupledto the support member; a locking device for locking the position of thetubular member relative to the support member; a first adjustableexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a second adjustableexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a packer coupled to thesupport member; and an actuator for displacing one or more of thesealing assembly, first and second adjustable expansion devices, andpacker relative to the support member.

According to another aspect of the present invention, an apparatus forcutting a tubular member is provided that includes a support member; anda plurality of movable cutting elements coupled to the support member.

According to another aspect of the present invention, an apparatus forengaging a tubular member is provided that includes a support member;and a plurality of movable elements coupled to the support member.

According to another aspect of the present invention, an apparatus forgripping a tubular member is provided that includes a plurality ofmovable gripping elements.

According to another aspect of the present invention, an actuator isprovided that includes a tubular housing; a tubular piston rod movablycoupled to and at least partially positioned within the housing; aplurality of annular piston chambers defined by the tubular housing andthe tubular piston rod; and a plurality of tubular pistons coupled tothe tubular piston rod, each tubular piston movably positioned within acorresponding annular piston chamber.

According to another aspect of the present invention, an apparatus forcontrolling a packer is provided that includes a tubular support member;one or more drag blocks releasably coupled to the tubular supportmember; and a tubular stinger coupled to the tubular support member forengaging the packer.

According to another aspect of the present invention, a packer isprovided that includes a support member defining a passage; a shoecomprising a float valve coupled to an end of the support member; one ormore compressible packer elements movably coupled to the support member;and a sliding sleeve valve movably positioned within the passage of thesupport member.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming an expandable tubularmember within a borehole having a preexisting wellbore casing isprovided that includes positioning the tubular member within theborehole in overlapping relation to the wellbore casing; radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section; and radially expanding and plastically deforming aportion of the tubular member above the bell section comprising aportion of the tubular member that overlaps with the wellbore casing;wherein the inside diameter of the bell section is greater than theinside diameter of the radially expanded and plastically deformedportion of the tubular member above the bell section.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning an adjustable expansion device within a first expandabletubular member; supporting the first expandable tubular member and theadjustable expansion device within a borehole; lowering the adjustableexpansion device out of the first expandable tubular member; increasingthe outside dimension of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;positioning the adjustable expansion device within a second expandabletubular member; supporting the second expandable tubular member and theadjustable expansion device within the borehole in overlapping relationto the first expandable tubular member; lowering the adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the adjustable expansion device; and displacingthe adjustable expansion device upwardly relative to the secondexpandable tubular member n times to radially expand and plasticallydeform n portions of the second expandable tubular member within theborehole.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning anadjustable expansion device within the expandable tubular member;supporting the expandable tubular member and the adjustable expansiondevice within the borehole; lowering the adjustable expansion device outof the expandable tubular member; increasing the outside dimension ofthe adjustable expansion device; displacing the adjustable expansionmandrel upwardly relative to the expandable tubular member n times toradially expand and plastically deform n portions of the expandabletubular member within the borehole; and pressurizing an interior regionof the expandable tubular member above the adjustable expansion deviceduring the radial expansion and plastic deformation of the expandabletubular member within the borehole.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning an adjustable expansion device within a first expandabletubular member; supporting the first expandable tubular member and theadjustable expansion device within a borehole; lowering the adjustableexpansion device out of the first expandable tubular member; increasingthe outside dimension of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;pressurizing an interior region of the first expandable tubular memberabove the adjustable expansion device during the radial expansion andplastic deformation of the first expandable tubular member within theborehole; positioning the adjustable expansion mandrel within a secondexpandable tubular member; supporting the second expandable tubularmember and the adjustable expansion mandrel within the borehole inoverlapping relation to the first expandable tubular member; loweringthe adjustable expansion mandrel out of the second expandable tubularmember; increasing the outside dimension of the adjustable expansionmandrel; displacing the adjustable expansion mandrel upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole; and pressurizing an interior region of the secondexpandable tubular member above the adjustable expansion mandrel duringthe radial expansion and plastic deformation of the second expandabletubular member within the borehole.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning first andsecond adjustable expansion devices within the expandable tubularmember; supporting the expandable tubular member and the first andsecond adjustable expansion devices within the borehole; lowering thefirst adjustable expansion device out of the expandable tubular member;increasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the expandable tubular member to radially expand andplastically deform a lower portion of the expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning first and second adjustable expansion devices within a firstexpandable tubular member; supporting the first expandable tubularmember and the first and second adjustable expansion devices within aborehole; lowering the first adjustable expansion device out of thefirst expandable tubular member; increasing the outside dimension of thefirst adjustable expansion device; displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the first expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; displacingthe second adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deformportions of the first expandable tubular member above the lower portionof the expandable tubular member; positioning first and secondadjustable expansion devices within a second expandable tubular member;supporting the first expandable tubular member and the first and secondadjustable expansion devices within the borehole in overlapping relationto the first expandable tubular member; lowering the first adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the first adjustable expansion device;displacing the first adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform a lower portion of the second expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the second expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; and displacing the second adjustableexpansion device upwardly relative to the second expandable tubularmember to radially expand and plastically deform portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member; wherein the outside dimension of the firstadjustable expansion device is greater than the outside dimension of thesecond adjustable expansion device.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning first andsecond adjustable expansion devices within the expandable tubularmember; supporting the expandable tubular member and the first andsecond adjustable expansion devices within the borehole; lowering thefirst adjustable expansion device out of the expandable tubular member;increasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the expandable tubular member to radially expand andplastically deform a lower portion of the expandable tubular member;pressurizing an interior region of the expandable tubular member abovethe first adjustable expansion device during the radial expansion of thelower portion of the expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to theexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the expandable tubular member toradially expand and plastically deform portions of the expandabletubular member above the lower portion of the expandable tubular member;and pressurizing an interior region of the expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the expandable tubular member above the lower portionof the expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning first and second adjustable expansion devices within a firstexpandable tubular member; supporting the first expandable tubularmember and the first and second adjustable expansion devices within aborehole; lowering the first adjustable expansion device out of thefirst expandable tubular member; increasing the outside dimension of thefirst adjustable expansion device; displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; pressurizing an interior region of thefirst expandable tubular member above the first adjustable expansiondevice during the radial expansion of the lower portion of the firstexpandable tubular member by the first adjustable expansion device;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the first expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the first expandable tubular member toradially expand and plastically deform portions of the first expandabletubular member above the lower portion of the expandable tubular member;pressurizing an interior region of the first expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the first expandable tubular member above the lowerportion of the first expandable tubular member by the second adjustableexpansion device; positioning first and second adjustable expansiondevices within a second expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within the borehole in overlapping relation to the firstexpandable tubular member; lowering the first adjustable expansiondevice out of the second expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deform alower portion of the second expandable tubular member; pressurizing aninterior region of the second expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the second expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the secondexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the second expandable tubularmember to radially expand and plastically deform portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member; and pressurizing an interior region of thesecond expandable tubular member above the second adjustable expansiondevice during the radial expansion of the portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member by the second adjustable expansion device;wherein the outside dimension of the first adjustable expansion deviceis greater than the outside dimension of the second adjustable expansiondevice.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes supporting theexpandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; increasing the size of theadjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform a portionof the expandable tubular member.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing within a borehole that includesa preexisting wellbore casing is provided that includes supporting theexpandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; increasing the size of theadjustable expansion device; displacing the adjustable expansion deviceupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform a portion of theexpandable tubular member; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform the remaining portion of the expandabletubular member and a portion of the preexisting wellbore casing thatoverlaps with an end of the remaining portion of the expandable tubularmember.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming a tubular member isprovided that includes positioning the tubular member within apreexisting structure; radially expanding and plastically deforming alower portion of the tubular member to form a bell section; and radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming a tubular member isprovided that includes applying internal pressure to the inside surfaceof the tubular member at a plurality of discrete location separated fromone another.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole having a preexisting wellbore casing isprovided that includes means for positioning the tubular member withinthe borehole in overlapping relation to the wellbore casing; means forradially expanding and plastically deforming a portion of the tubularmember to form a bell section; and means for radially expanding andplastically deforming a portion of the tubular member above the bellsection comprising a portion of the tubular member that overlaps withthe wellbore casing; wherein the inside diameter of the bell section isgreater than the inside diameter of the radially expanded andplastically deformed portion of the tubular member above the bellsection.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning an adjustable expansion device within a first expandabletubular member; means for supporting the first expandable tubular memberand the adjustable expansion device within a borehole; means forlowering the adjustable expansion device out of the first expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; means for displacing the adjustableexpansion device upwardly relative to the first expandable tubularmember m times to radially expand and plastically deform m portions ofthe first expandable tubular member within the borehole; means forpositioning the adjustable expansion device within a second expandabletubular member; means for supporting the second expandable tubularmember and the adjustable expansion device within the borehole inoverlapping relation to the first expandable tubular member; means forlowering the adjustable expansion device out of the second expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the second expandable tubularmember n times to radially expand and plastically deform n portions ofthe second expandable tubular member within the borehole.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningan adjustable expansion device within the expandable tubular member;means for supporting the expandable tubular member and the adjustableexpansion device within the borehole; means for lowering the adjustableexpansion device out of the expandable tubular member; means forincreasing the outside dimension of the adjustable expansion device;means for displacing the adjustable expansion mandrel upwardly relativeto the expandable tubular member n times to radially expand andplastically deform n portions of the expandable tubular member withinthe borehole; and means for pressurizing an interior region of theexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the expandable tubularmember within the borehole.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning an adjustable expansion device within a first expandabletubular member; means for supporting the first expandable tubular memberand the adjustable expansion device within a borehole; means forlowering the adjustable expansion device out of the first expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; means for displacing the adjustableexpansion device upwardly relative to the first expandable tubularmember m times to radially expand and plastically deform m portions ofthe first expandable tubular member within the borehole; means forpressurizing an interior region of the first expandable tubular memberabove the adjustable expansion device during the radial expansion andplastic deformation of the first expandable tubular member within theborehole; means for positioning the adjustable expansion mandrel withina second expandable tubular member; means for supporting the secondexpandable tubular member and the adjustable expansion mandrel withinthe borehole in overlapping relation to the first expandable tubularmember; means for lowering the adjustable expansion mandrel out of thesecond expandable tubular member; means for increasing the outsidedimension of the adjustable expansion mandrel; means for displacing theadjustable expansion mandrel upwardly relative to the second expandabletubular member n times to radially expand and plastically deform nportions of the second expandable tubular member within the borehole;and means for pressurizing an interior region of the second expandabletubular member above the adjustable expansion mandrel during the radialexpansion and plastic deformation of the second expandable tubularmember within the borehole.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningfirst and second adjustable expansion devices within the expandabletubular member; means for supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;means for lowering the first adjustable expansion device out of theexpandable tubular member; means for increasing the outside dimension ofthe first adjustable expansion device; means for displacing the firstadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform a lower portion of theexpandable tubular member; means for displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the expandable tubular member; means for decreasing theoutside dimension of the first adjustable expansion device andincreasing the outside dimension of the second adjustable expansiondevice; means for displacing the second adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform portions of the expandable tubular member abovethe lower portion of the expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning first and second adjustable expansion devices within afirst expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; means for lowering the first adjustableexpansion device out of the first expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the first expandable tubular member to radially expand andplastically deform a lower portion of the first expandable tubularmember; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe first expandable tubular member to radially expand and plasticallydeform portions of the first expandable tubular member above the lowerportion of the expandable tubular member; means for positioning firstand second adjustable expansion devices within a second expandabletubular member; means for supporting the first expandable tubular memberand the first and second adjustable expansion devices within theborehole in overlapping relation to the first expandable tubular member;means for lowering the first adjustable expansion device out of thesecond expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deform alower portion of the second expandable tubular member; means fordisplacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the second expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; and means for displacing the secondadjustable expansion device upwardly relative to the second expandabletubular member to radially expand and plastically deform portions of thesecond expandable tubular member above the lower portion of the secondexpandable tubular member; wherein the outside dimension of the firstadjustable expansion device is greater than the outside dimension of thesecond adjustable expansion device.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningfirst and second adjustable expansion devices within the expandabletubular member; means for supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;means for lowering the first adjustable expansion device out of theexpandable tubular member; means for increasing the outside dimension ofthe first adjustable expansion device; means for displacing the firstadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform a lower portion of theexpandable tubular member; means for pressurizing an interior region ofthe expandable tubular member above the first adjustable expansiondevice during the radial expansion of the lower portion of theexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; means for displacing the secondadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform portions of theexpandable tubular member above the lower portion of the expandabletubular member; and means for pressurizing an interior region of theexpandable tubular member above the second adjustable expansion deviceduring the radial expansion of the portions of the expandable tubularmember above the lower portion of the expandable tubular member by thesecond adjustable expansion device; wherein the outside dimension of thefirst adjustable expansion device is greater than the outside dimensionof the second adjustable expansion device.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning first and second adjustable expansion devices within afirst expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; means for lowering the first adjustableexpansion device out of the first expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform a lower portion of the first expandabletubular member; means for pressurizing an interior region of the firstexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the first expandabletubular member by the first adjustable expansion device; means fordisplacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the first expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; means for displacing the secondadjustable expansion device upwardly relative to the first expandabletubular member to radially expand and plastically deform portions of thefirst expandable tubular member above the lower portion of theexpandable tubular member; means for pressurizing an interior region ofthe first expandable tubular member above the second adjustableexpansion device during the radial expansion of the portions of thefirst expandable tubular member above the lower portion of the firstexpandable tubular member by the second adjustable expansion device;means for positioning first and second adjustable expansion deviceswithin a second expandable tubular member; means for supporting thefirst expandable tubular member and the first and second adjustableexpansion devices within the borehole in overlapping relation to thefirst expandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the second expandable tubular member to radiallyexpand and plastically deform a lower portion of the second expandabletubular member; means for pressurizing an interior region of the secondexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the secondexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; and means forpressurizing an interior region of the second expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the second expandable tubular member above the lowerportion of the second expandable tubular member by the second adjustableexpansion device; wherein the outside dimension of the first adjustableexpansion device is greater than the outside dimension of the secondadjustable expansion device.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for supportingthe expandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; means for increasing the size ofthe adjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the expandable tubular memberusing the hydraulic actuator to radially expand and plastically deform aportion of the expandable tubular member.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing within a borehole that includesa preexisting wellbore casing is provided that includes means forsupporting the expandable tubular member, an hydraulic actuator, and anadjustable expansion device within the borehole; means for increasingthe size of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the expandable tubularmember using the hydraulic actuator to radially expand and plasticallydeform a portion of the expandable tubular member; and means fordisplacing the adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform theremaining portion of the expandable tubular member and a portion of thepreexisting wellbore casing that overlaps with an end of the remainingportion of the expandable tubular member.

According to another aspect of the present invention, a system forradially expanding and plastically deforming a tubular member isprovided that includes means for positioning the tubular member within apreexisting structure; means for radially expanding and plasticallydeforming a lower portion of the tubular member to form a bell section;and means for radially expanding and plastically deforming a portion ofthe tubular member above the bell section.

According to another aspect of the present invention, a system ofradially expanding and plastically deforming a tubular member isprovided that includes a support member; and means for applying internalpressure to the inside surface of the tubular member at a plurality ofdiscrete location separated from one another coupled to the supportmember.

According to another aspect of the present invention, a method ofcutting a tubular member is provided that includes positioning aplurality of cutting elements within the tubular member; and bringingthe cutting elements into engagement with the tubular member.

According to another aspect of the present invention, a method ofgripping a tubular member is provided that includes positioning aplurality of gripping elements within the tubular member; bringing thegripping elements into engagement with the tubular member. In anexemplary embodiment, bringing the gripping elements into engagementwith the tubular member includes displacing the gripping elements in anaxial direction; and displacing the gripping elements in a radialdirection.

According to another aspect of the present invention, a method ofoperating an actuator is provided that includes pressurizing a pluralityof pressure chamber.

According to another aspect of the present invention, a method ofinjecting a hardenable fluidic sealing material into an annulus betweena tubular member and a preexisting structure is provided that includespositioning the tubular member into the preexisting structure; sealingoff an end of the tubular member; operating a valve within the end ofthe tubular member; and injecting a hardenable fluidic sealing materialthrough the valve into the annulus between the tubular member and thepreexisting structure.

According to another aspect of the present invention, a system forcutting a tubular member is provided that includes means for positioninga plurality of cutting elements within the tubular member; and means forbringing the cutting elements into engagement with the tubular member.

According to another aspect of the present invention, a system forgripping a tubular member is provided that includes means forpositioning a plurality of gripping elements within the tubular member;and means for bringing the gripping elements into engagement with thetubular member.

According to another aspect of the present invention, an actuator systemis provided that includes a support member; and means for pressurizing aplurality of pressure chambers coupled to the support member. In anexemplary embodiment, the system further includes means for transmittingtorsional loads.

According to another aspect of the present invention, a system forinjecting a hardenable fluidic sealing material into an annulus betweena tubular member and a preexisting structure is provided that includesmeans for positioning the tubular member into the preexisting structure;means for sealing off an end of the tubular member; means for operatinga valve within the end of the tubular member; and means for injecting ahardenable fluidic sealing material through the valve into the annulusbetween the tubular member and the preexisting structure.

According to another aspect of the present invention, a method ofengaging a tubular member is provided that includes positioning aplurality of elements within the tubular member; and bringing theelements into engagement with the tubular member.

According to another aspect of the present invention, a system forengaging a tubular member is provided that includes means forpositioning a plurality of elements within the tubular member; and meansfor bringing the elements into engagement with the tubular member. In anexemplary embodiment, the elements include a first group of elements;and a second group of elements; wherein the first group of elements areinterleaved with the second group of elements.

According to another aspect of the present invention, a locking devicefor locking a tubular member to a support member is provided thatincludes a plurality of circumferentially spaced apart locking elementscoupled to the support member for engaging an interior surface of thetubular member; a plurality of spring elements coupled to the supportmember for biasing corresponding locking elements out of engagement withthe interior surface of the tubular member; a releasable retainingelement releasably coupled to the support member for releasablyretaining the locking elements in engagement with the interior surfaceof the tubular member; an actuator coupled to the support member forcontrollably displacing the retaining element relative to the lockingelements; and a sensor coupled to the support member for sensing anoperating condition within the tubular member for controllablydisplacing the retaining element relative to the locking elements.

According to another aspect of the present invention, a method oflocking a tubular member to a support member is provided that includesengaging the interior surface of the tubular member at a plurality ofcircumferentially spaced apart locations using one or more engagementmembers; and disengaging the engagement members from the interiorsurface of the tubular member if an operating condition within thetubular member exceeds a predetermined amount; wherein the engagementmembers are biased out of engagement with the tubular member.

According to another aspect of the present invention, a system forlocking a tubular member to a support member is provided that includesmeans for engaging the interior surface of the tubular member at aplurality of circumferentially spaced apart locations using one or moreengagement members; and means for disengaging the engagement membersfrom the interior surface of the tubular member if an operatingcondition within the tubular member exceeds a predetermined amount;wherein the engagement members are biased out of engagement with thetubular member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional illustration of an embodiment ofa system for radially expanding and plastically deforming wellborecasing, including a tubular support member, a casing cutter, a ballgripper for gripping a wellbore casing, a force multiplier tensionactuator, a safety sub, a cup sub, a casing lock, an extension actuator,a bell section adjustable expansion cone assembly, a casing sectionadjustable expansion cone assembly, a packer setting tool, a packer, astinger, and an expandable wellbore casing, during the placement of thesystem within a wellbore.

FIG. 2 is a fragmentary cross-sectional illustration of the system ofFIG. 1 during the subsequent displacement of the bell section adjustableexpansion cone assembly, the casing section adjustable expansion coneassembly, the packer setting tool, the packer, and the stingerdownwardly out of the end of the expandable wellbore casing and theexpansion of the size of the bell section adjustable expansion coneassembly and the casing section adjustable expansion cone assembly.

FIG. 3 is a fragmentary cross-sectional illustration of the system ofFIG. 2 during the subsequent operation of the tension actuator todisplace the bell section adjustable expansion cone assembly upwardlyinto the end of the expandable wellbore casing to form a bell section inthe end of the expandable wellbore casing.

FIG. 4 is a fragmentary cross-sectional illustration of the system ofFIG. 3 during the subsequent reduction of the bell section adjustableexpansion cone assembly.

FIG. 5 is a fragmentary cross-sectional illustration of the system ofFIG. 4 during the subsequent upward displacement of the expanded casingsection adjustable expansion cone assembly to radially expand theexpandable wellbore casing.

FIG. 6 is a fragmentary cross-sectional illustration of the system ofFIG. 5 during the subsequent lowering of the tubular support member,casing cutter, ball gripper, a force multiplier tension actuator, safetysub, cup sub, casing lock, extension actuator, bell section adjustableexpansion cone assembly, casing section adjustable expansion coneassembly, packer setting tool, packer, and stinger and subsequentsetting of the packer within the expandable wellbore casing above thebell section.

FIG. 7 is a fragmentary cross-sectional illustration of the system ofFIG. 6 during the subsequent injection of fluidic materials into thesystem to displace the expanded casing section adjustable expansion coneassembly upwardly through the expandable wellbore casing to radiallyexpand and plastically deform the expandable wellbore casing.

FIG. 8 is a fragmentary cross-sectional illustration of the system ofFIG. 7 during the subsequent injection of fluidic materials into thesystem to displace the expanded casing section adjustable expansion coneassembly upwardly through the expandable wellbore casing and asurrounding preexisting wellbore casing to radially expand andplastically deform the overlapping expandable wellbore casing and thesurrounding preexisting wellbore casing.

FIG. 9 is a fragmentary cross-sectional illustration of the system ofFIG. 8 during the subsequent operation of the casing cutter to cut offan end of the expandable wellbore casing.

FIG. 10 is a fragmentary cross-sectional illustration of the system ofFIG. 9 during the subsequent removal of the cut off end of theexpandable wellbore casing.

FIGS. 11-1 and 11-2, 11A1 to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F,11G, 11H, 11I, 11 j, 11K, 11L, 11M, 11N, 11O, 11P, 11Q, 11R, 11S, 11T,11U, 11V, 11W, 11X, 11Y, 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4,11AC1 to 11AC4, 11AD, and 11AE are fragmentary cross-sectional andperspective illustrations of an exemplary embodiment of a casing cutterassembly.

FIGS. 12A1 to 12A4 and 12C1 to 12C4 are fragmentary cross-sectionalillustrations of an exemplary embodiment of a ball gripper assembly.

FIG. 12B is a top view of a portion of the ball gripper assembly ofFIGS. 12A1 to 12A4 and 12C1 to 12C4.

FIGS. 13A1 to 13A8 and 13B1 to 13B7 are fragmentary cross-sectionalillustrations of an exemplary embodiment of a tension actuator assembly.

FIG. 14A is a fragmentary cross-sectional illustrations of an exemplaryembodiment of a safety sub assembly.

FIGS. 14A, 14B and 14C are fragmentary cross-sectional and perspectiveillustrations of an exemplary embodiment of a cup seal assembly.

FIGS. 15-1, 15-2, 15A1, 15A2, 15B1, 15B2, 15C1, 15C2, 15D, 15E1 to 15E5,15F1 to 15F5, and 15G1 to 15G5 are fragmentary cross sectionalillustrations of an exemplary embodiment of an extension actuator andcasing lock assembly.

FIGS. 16-1 and 16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F,16G, 16H, 16I, 16 j, 16K, 16L, 16M, 16N, 16O, 16P, 16R, 16S, 16T, 16U,16V, 16W, 16 x, 16Y, 16Z1 to 16Z4, 16M1 to 16AA4, 16AB1 to 16AB4, 16AC1to 16AC4, 16AD, and 16AE are fragmentary cross-sectional and perspectiveillustrations of an exemplary embodiment of an adjustable bell sectionexpansion cone assembly.

FIGS. 17-1 and 17-2, 17A1 to 17A2, 17B1 to 17B2, 17C, 17D, 17E, 17F,17G, 17H, 17I, 17 j, 17K, 17L, 17M, 17N, 17O, 17P, 17R, 17S, 17T, 17U,17V, 17W, 17 x, 17Y, 17Z1-17Z4, 17AA1 to 17AA4, 17AB1 to 17AB4, 17AC1 to17AC4, 17AD, and 17AE are fragmentary cross-sectional and perspectiveillustrations of an exemplary embodiment of an adjustable casingexpansion cone assembly.

FIGS. 18A to 18C is a fragmentary cross-sectional illustration of anexemplary embodiment of a packer setting tool assembly.

FIGS. 19-1 to 19-5 is a fragmentary cross-sectional illustration of anexemplary embodiment of a packer assembly.

FIGS. 20A1 to 20A5, 20B1 to 20B5, 20C1 to 20C5, 20D1 to 20D5, 20E1 to20E6, 20F1 to 20F6, 20G1 to 20G6, and 20H1 to 20H5, are fragmentarycross-sectional illustrations of an exemplary embodiment of theoperation of the packer setting tool and the packer assembly of FIGS.18A to 18C and 19-1 to 19-5.

FIGS. 21 and 21A to 21AX are fragmentary perspective and cross-sectionalillustrations of an alternative embodiment of the packer assembly.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIGS. 1-10, an exemplary embodiment of a system10 for radially expanding and plastically deforming a wellbore casingincludes a conventional tubular support 12 having an end that is coupledto an end of a casing cutter assembly 14. In an exemplary embodiment,the casing cutter assembly 14 may be, or may include elements, of one ormore conventional commercially available casing cutters for cuttingwellbore casing, or equivalents thereof.

An end of a ball gripper assembly 16 is coupled to another end of thecasing cutter assembly 14. In an exemplary embodiment, the ball gripperassembly 14 may be, or may include elements, of one or more conventionalcommercially available ball grippers, or other types of grippingdevices, for gripping wellbore casing, or equivalents thereof.

An end of a tension actuator assembly 18 is coupled to another end ofthe ball gripper assembly 16. In an exemplary embodiment, the tensionactuator assembly 18 may be, or may include elements, of one or moreconventional commercially actuators, or equivalents thereof.

An end of a safety sub assembly 20 is coupled to another end of thetension actuator assembly 18. In an exemplary embodiment, the safety subassembly 20 may be, or may include elements, of one or more conventionalapparatus that provide quick connection and/or disconnection of tubularmembers, or equivalents thereof.

An end of a sealing cup assembly 22 is coupled to another end of thesafety sub assembly 20. In an exemplary embodiment, the sealing cupassembly 22 may be, or may include elements, of one or more conventionalsealing cup assemblies, or other types of sealing assemblies, thatsealingly engage the interior surfaces of surrounding tubular members,or equivalents thereof.

An end of a casing lock assembly 24 is coupled to another end of thesealing cup assembly 22. In an exemplary embodiment, the casing lockassembly 24 may be, or may include elements, of one or more conventionalcasing lock assemblies that lock the position of wellbore casing, orequivalents thereof.

An end of an extension actuator assembly 26 is coupled to another end ofthe casing lock assembly 24. In an exemplary embodiment, the extensionactuator assembly 26 may be, or may include elements, of one or moreconventional actuators, or equivalents thereof.

An end of an adjustable bell section expansion cone assembly 28 iscoupled to another end of the extension actuator assembly 26. In anexemplary embodiment, the adjustable bell section expansion coneassembly 28 may be, or may include elements, of one or more conventionaladjustable expansion devices for radially expanding and plasticallydeforming wellbore casing, or equivalents thereof.

An end of an adjustable casing expansion cone assembly 30 is coupled toanother end of the adjustable bell section expansion cone assembly 28.In an exemplary embodiment, the adjustable casing expansion coneassembly 30 may be, or may include elements, of one or more conventionaladjustable expansion devices for radially expanding and plasticallydeforming wellbore casing, or equivalents thereof.

An end of a packer setting tool assembly 32 is coupled to another end ofthe adjustable casing expansion cone assembly 30. In an exemplaryembodiment, the packer setting tool assembly 32 may be, or may includeelements, of one or more conventional adjustable expansion devices forcontrolling the operation of a conventional packer, or equivalentsthereof.

An end of a stinger assembly 34 is coupled to another end of the packersetting tool assembly 32. In an exemplary embodiment, the stingerassembly 34 may be, or may include elements, of one or more conventionaldevices for engaging a conventional packer, or equivalents thereof.

An end of a packer assembly 36 is coupled to another end of the stingerassembly 34. In an exemplary embodiment, the packer assembly 36 may be,or may include elements, of one or more conventional packers.

In an exemplary embodiment, one or more of the elements of the system 10may be omitted, at least in part, and/or combined, at least in part,with one or more of the other elements of the system.

As illustrated in FIG. 1, in an exemplary embodiment, during operationof the system 10, an expandable wellbore casing 100 is coupled to andsupported by the casing lock assembly 24 of the system. The system 10 isthen positioned within a wellbore 102 that traverses a subterraneanformation 104 and includes a preexisting wellbore casing 106.

As illustrated in FIG. 2, in an exemplary embodiment, the extensionactuator assembly 26 is then operated to move the adjustable bellsection expansion cone assembly 28, adjustable casing expansion coneassembly 30, packer setting tool assembly 32, stinger assembly 34,packer assembly 36 downwardly in a direction 108 and out of an end ofthe expandable wellbore casing 100. After the adjustable bell sectionexpansion cone assembly 28 and adjustable casing expansion cone assembly30 have been moved to a position out of the end of the expandablewellbore casing 100, the adjustable bell section expansion cone assemblyand adjustable casing expansion cone assembly are then operated toincrease the outside diameters of the expansion cone assemblies. In anexemplary embodiment, the increased outside diameter of the adjustablebell section expansion cone assembly 28 is greater than the increasedoutside diameter of the adjustable casing expansion cone assembly 30.

As illustrated in FIG. 3, in an exemplary embodiment, the ball gripperassembly 16 is then operated to engage and hold the position of theexpandable tubular member 100 stationary relative to the tubular supportmember 12. The tension actuator assembly 18 is then operated to move theadjustable bell section expansion cone assembly 28, adjustable casingexpansion cone assembly 30, packer setting tool assembly 32, stingerassembly 34, packer assembly 36 upwardly in a direction 110 into andthrough the end of the expandable wellbore casing 100. As a result, theend of the expandable wellbore casing 100 is radially expanded andplastically deformed by the adjustable bell section expansion coneassembly 28 to form a bell section 112. In an exemplary embodiment,during the operation of the system 10 described above with reference toFIG. 3, the casing lock assembly 24 may or may not be coupled to theexpandable wellbore casing 100.

In an exemplary embodiment, the length of the end of the expandablewellbore casing 100 that is radially expanded and plastically deformedby the adjustable bell section expansion cone assembly 28 is limited bythe stroke length of the tension actuator assembly 18. In an exemplaryembodiment, once the tension actuator assembly 18 completes a stroke,the ball gripper assembly 16 is operated to release the expandabletubular member 100, and the tubular support 12 is moved upwardly topermit the tension actuator assembly to be re-set. In this manner, thelength of the bell section 112 can be further extended by continuing tostroke and then re-set the position of the tension actuator assembly 18.Note, that, during the upward movement of the tubular support 12 tore-set the position of the tension actuator assembly 18, the expandabletubular wellbore casing 100 is supported by the expansion surfaces ofthe adjustable bell section expansion cone assembly 28.

As illustrated in FIG. 4, in an exemplary embodiment, the casing lockassembly 24 is then operated to engage and maintain the position of theexpandable wellbore casing 100 stationary relative to the tubularsupport 12. The adjustable bell section expansion cone assembly 28,adjustable casing expansion cone assembly 30, packer setting toolassembly 32, stinger assembly 34, and packer assembly 36 are displaceddownwardly into the bell section 112 in a direction 114 relative to theexpandable wellbore casing 100 by operating the extension actuator 26and/or by displacing the system 10 downwardly in the direction 114relative to the expandable wellbore casing. After the adjustable bellsection expansion cone assembly 28 and adjustable casing expansion coneassembly 30 have been moved downwardly in the direction 114 into thebell section 112 of the expandable wellbore casing 100, the adjustablebell section expansion cone assembly is then operated to decrease theoutside diameter of the adjustable bell section expansion cone assembly.In an exemplary embodiment, the decreased outside diameter of theadjustable bell section expansion cone assembly 28 is less than theincreased outside diameter of the adjustable casing expansion coneassembly 30. In an exemplary embodiment, during the operation of thesystem illustrated and described above with reference to FIG. 4, theball gripper 16 may or may not be operated to engage the expandablewellbore casing 100.

As illustrated in FIG. 5, in an exemplary embodiment, the casing lockassembly 24 is then disengaged from the expandable wellbore casing 100and fluidic material 116 is then injected into the system 10 through thetubular support 12 to thereby pressurize an annulus 118 defined withinthe expandable wellbore casing below the cup sub assembly 22. As aresult, a pressure differential is created across the cup seal assembly22 that causes the cup seal assembly to apply a tensile force in thedirection 120 to the system 10. As a result, the system 10 is displacedupwardly in the direction 120 relative to the expandable wellbore casing100 thereby pulling the adjustable casing expansion cone assembly 30upwardly in the direction 120 through the expandable wellbore casingthereby radially expanding and plastically deforming the expandablewellbore casing.

In an exemplary embodiment, the tension actuator assembly 16 may also beoperated during the injection of the fluidic material 116 to displacethe adjustable casing expansion cone assembly 30 upwardly relative tothe tubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100.

As illustrated in FIG. 6, in an exemplary embodiment, the radialexpansion and plastic deformation of the expandable wellbore casingusing the adjustable casing expansion cone assembly 30 continues untilthe packer assembly 36 is positioned within a portion of the expandabletubular member above the bell section 112. The packer assembly 36 maythen be operated to engage the interior surface of the expandablewellbore casing 100 above the bell section 112.

In an exemplary embodiment, after the packer assembly 36 is operated toengage the interior surface of the expandable wellbore casing 100 abovethe bell section 112, a hardenable fluidic sealing material 122 may thenbe injected into the system 10 through the tubular support 12 and thenout of the system through the packer assembly to thereby permit theannulus between the expandable wellbore casing and the wellbore 102 tobe filled with the hardenable fluidic sealing material. The hardenablefluidic sealing material 122 may then be allowed to cure to form a fluidtight annulus between the expandable wellbore casing 100 and thewellbore 102, before, during, or after the completion of the radialexpansion and plastic deformation of the expandable wellbore casing.

As illustrated in FIG. 7, in an exemplary embodiment, the fluidicmaterial 116 is then re-injected into the system 10 through the tubularsupport 12 to thereby re-pressurize the annulus 118 defined within theexpandable wellbore casing below the cup sub assembly 22. As a result, apressure differential is once again created across the cup seal assembly22 that causes the cup seal assembly to once again apply a tensile forcein the direction 120 to the system 10. As a result, the system 10 isdisplaced upwardly in the direction 120 relative to the expandablewellbore casing 100 thereby pulling the adjustable casing expansion coneassembly 30 upwardly in the direction 120 through the expandablewellbore casing thereby radially expanding and plastically deforming theexpandable wellbore casing and disengaging the stinger assembly 34 fromthe packer assembly 36. In an exemplary embodiment, during thisoperational mode, the packer assembly 36 prevents the flow of fluidicmaterials out of the expandable wellbore casing 100. As a result, thepressurization of the annulus 118 is rapid and efficient therebyenhancing the operational efficiency of the subsequent radial expansionand plastic deformation of the expandable wellbore casing 100.

In an exemplary embodiment, the tension actuator assembly 16 may also beoperated during the re-injection of the fluidic material 116 to displacethe adjustable casing expansion cone assembly 30 upwardly relative tothe tubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100.

As illustrated in FIG. 8, in an exemplary embodiment, the radialexpansion and plastic deformation of the expandable wellbore casingusing the adjustable casing expansion cone assembly 30 continues untilthe adjustable casing expansion cone assembly 30 reaches the portion 124of the expandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106. At which point, the system 10 may radially expandthe portion 124 of the expandable wellbore casing 100 that overlaps withthe preexisting wellbore casing 106 and the surrounding portion of thepreexisting wellbore casing. Consequently, in an exemplary embodiment,during the radial expansion of the portion 124 of the expandablewellbore casing 100 that overlaps with the preexisting wellbore casing106, the tension actuator assembly 16 is also operated to displace theadjustable casing expansion cone assembly 30 upwardly relative to thetubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100 and the preexistingwellbore casing 106 during the radial expansion of the portion 124 ofthe expandable wellbore casing that overlaps with the preexistingwellbore casing.

As illustrated in FIG. 9, in an exemplary embodiment, the entire lengthof the portion 124 of the expandable wellbore casing 100 that overlapswith the preexisting wellbore casing 106 is not radially expanded andplastically deformed. Rather, only part of the portion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 is radially expanded and plastically deformed. Theremaining part of the portion 124 of the expandable wellbore casing 100that overlaps with the preexisting wellbore casing 106 is then cut awayby operating the casing cutter assembly 14.

As illustrated in FIG. 10, the remaining part of the portion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 that is cut away by operating the casing cutterassembly 14 is then also carried out of the wellbore 102 using thecasing cutter assembly.

Furthermore, in an exemplary embodiment, the inside diameter of theexpandable wellbore casing 100 above the bell section 112 is equal tothe inside diameter of the portion of the preexisting wellbore casing106 that does not overlap with the expandable wellbore casing 100. As aresult, a wellbore casing is constructed that includes overlappingwellbore casings that together define an internal passage having aconstant cross-sectional area.

In an exemplary embodiment, one or more of the operational elements ofthe system 10 may be omitted, at least in part, and/or combined, atleast in part, with one or more of the other operational elements of thesystem.

In several exemplary embodiments, the system 10 includes one or more ofthe methods and apparatus disclosed in one or more of the following: (1)U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser.No. 09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, whichclaims priority from provisional application 60/121,702, filed on Feb.25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb.10, 2000, which claims priority from provisional application 60/119,611,filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed asU.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. 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No. 09/969,922, filed on Oct. 3,2001, which is a continuation-in-part application of U.S. Pat. No.6,328,113, which was filed as U.S. patent application Ser. No.09/440,338, filed on Nov. 15, 1999, which claims priority fromprovisional application 60/108,558, filed on Nov. 16, 1998, (121) U.S.utility patent application Ser. No. 10/418,688, which was filed on Apr.18, 2003, as a division of U.S. utility patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (122) PCTpatent application serial no. PCT/US04/06246, filed on Feb. 26, 2004,(123) PCT patent application serial number PCT/US04/08170, filed on Mar.15, 2004, (124) PCT patent application serial number PCT/US04/08171,filed on Mar. 15, 2004, (125) PCT patent application serial numberPCT/US04/08073, filed on Mar. 18, 2004, (126) PCT patent applicationserial number PCT/US04/07711, filed on Mar. 11, 2004, (127) PCT patentapplication serial number PCT/US04/09434, filed on Mar. 26, 2004, (128)PCT patent application serial number PCT/US04/10317, filed on Apr. 2,2004, (129) PCT patent application serial number PCT/US04/10712, filedon Apr. 7, 2004, and (130) PCT patent application serial numberPCT/US04/10762, filed on Apr. 6, 2004, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, the casing cutter assembly 14 is providedand operates substantially, at least in part, as disclosed in one ormore of the following: (1) PCT patent application serial numberPCT/US03/29858, filed on Sep. 22, 2003, and/or (2) PCT patentapplication serial number PCT/US04/07711, filed on Mar. 11, 2004, and/or(3) PCT patent application serial number PCT/US04/09434, filed on Mar.26, 2004, and/or (4) PCT patent application serial numberPCT/US04/10317, filed on Apr. 2, 2004, (5) PCT patent application serialnumber PCT/US04/10712, filed on Apr. 7, 2004, and/or (6) PCT patentapplication serial number PCT/US04/10762, filed on Apr. 6, 2004, thedisclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 11-1 and 11-2, 11A1to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I, 11 j, 11K,11L, 11M, 11N, 11O, 11P, 11Q, 11R, 11S, 11T, 11U, 11V, 11W, 11 x, 11Y,11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and11AE, the casing cutter assembly 14 includes an upper tubular tool joint14002 that defines a longitudinal passage 14002 a and mounting holes,14002 b and 14002 c, and includes an internal threaded connection 14002d, an inner annular recess 14002 e, an inner annular recess 14002 f, andan internal threaded connection 14002 g. A tubular torque plate 14004that defines a longitudinal passage 14004 a and includescircumferentially spaced apart teeth 14004 b is received within, mateswith, and is coupled to the internal annular recess 14002 e of the uppertubular tool joint 14002.

Circumferentially spaced apart teeth 14006 a of an end of a tubularlower mandrel 14006 that defines a longitudinal passage 14006 b, aradial passage 14006 ba, and a radial passage 14006 bb and includes anexternal threaded connection 14006 c, an external flange 14006 d, anexternal annular recess 14006 e having a step 14006 f at one end, anexternal annular recess 14006 g, external teeth 14006 h, an externalthreaded connection 14006 i, and an external annular recess 14006 jengage the circumferentially spaced apart teeth 14004 b of the tubulartorque plate 14004. An internal threaded connection 14008 a of an end ofa tubular toggle bushing 14008 that defines a longitudinal passage 14008b, an upper longitudinal slot 14008 c, a lower longitudinal slot 14008d, mounting holes, 14008 e, 14008 f, 14008 g, 14008 h, 14008 i, 14008 j,14008 k, 140081, 14008 m, 14008 n, 14008 o, 14008 p, 14008 q, 14008 r,14008 s, 14008 t, 14008 u, 14008 v, 14008 w, 14008 x, 14008 xa, and14008 xb, and includes an external annular recess 14008 y, internalannular recess 14008 z, external annular recess 14008 aa, and anexternal annular recess 14008 ab receives and is coupled to the externalthreaded connection 14006 c of the tubular lower mandrel 14006.

A sealing element 14010 is received within the external annular recess14008 y of the tubular toggle bushing 14008 for sealing the interfacebetween the tubular toggle bushing and the upper tubular tool joint14002. A sealing element 14012 is received within the internal annularrecess 14008 z of the tubular toggle bushing 14008 for sealing theinterface between the tubular toggle bushing and the tubular lowermandrel 14006.

Mounting screws, 14014 a and 14014 b, mounted within and coupled to themounting holes, 14008 w and 14008 x, respectively, of the tubular togglebushing 14008 are also received within the mounting holes, 14002 b and14002 c, of the upper tubular tool joint 14002. Mounting pins, 14016 a,14016 b, 14016 c, 14016 d, and 14016 e, are mounted within the mountingholes, 14008 e, 14008 f, 14008 g, 14008 h, and 14008 i, respectively.Mounting pins, 14018 a, 14018 b, 14018 c, 14018 d, and 14018 e, aremounted within the mounting holes, 14008 t, 14008 s, 14008 r, 14008 q,and 14008 p, respectively. Mounting screws, 14020 a and 14020 b, aremounted within the mounting holes, 14008 u and 14008 v, respectively.

A first upper toggle link 14022 defines mounting holes, 14022 a and14022 b, for receiving the mounting pins, 14016 a and 14016 b, andincludes a mounting pin 14022 c at one end. A first lower toggle link14024 defines mounting holes, 14024 a, 14024 b, and 14024 c, forreceiving the mounting pins, 14022 c, 14016 c, and 14016 d, respectivelyand includes an engagement arm 14024 d. A first trigger 14026 defines amounting hole 14026 a for receiving the mounting pin 14016 e andincludes an engagement arm 14026 b at one end, an engagement member14026 c, and an engagement arm 14026 d at another end.

A second upper toggle link 14028 defines mounting holes, 14028 a and14028 b, for receiving the mounting pins, 14018 a and 14018 b, andincludes a mounting pin 14028 c at one end. A second lower toggle link14030 defines mounting holes, 14030 a, 14030 b, and 14030 c, forreceiving the mounting pins, 14028 c, 14018 c, and 14018 d, respectivelyand includes an engagement arm 14030 d. A second trigger 14032 defines amounting hole 14032 a for receiving the mounting pin 14018 e andincludes an engagement arm 14032 b at one end, an engagement member14032 c, and an engagement arm 14032 d at another end.

An end of a tubular spring housing 14034 that defines a longitudinalpassage 14034 a, mounting holes, 14034 b and 14034 c, and mountingholes, 14034 ba and 14034 ca, and includes an internal flange 14034 dand an internal annular recess 14034 e at one end, and an internalflange 14034 f, an internal annular recess 14034 g, an internal annularrecess 14034 h, and an external threaded connection 14034 i at anotherend receives and mates with the end of the tubular toggle bushing 14008.Mounting screws, 14035 a and 14035 b, are mounted within and coupled tothe mounting holes, 14008 xb and 14008 xa, respectively, of the tubulartoggle bushing 14008 and are received within the mounting holes, 14034ba and 14034 ca, respectively, of the tubular spring housing 14034.

A tubular retracting spring ring 14036 that defines mounting holes,14036 a and 14036 b, receives and mates with a portion of the tubularlower mandrel 14006 and is received within and mates with a portion ofthe tubular spring housing 14034. Mounting screws, 14038 a and 14038 b,are mounted within and coupled to the mounting holes, 14036 a and 14036b, respectively, of the tubular retracting spring ring 14036 and extendinto the mounting holes, 14034 b and 14034 c, respectively, of thetubular spring housing 14034.

Casing diameter sensor springs, 14040 a and 14040 b, are positionedwithin the longitudinal slots, 14008 c and 1408 d, respectively, of thetubular toggle bushing 14008 that engage the engagement members, 14026 cand 14032 c, and engagement arms, 14026 d and 14032 d, of the first andsecond triggers, 14026 and 14032, respectively. An inner flange 14042 aof an end of a tubular spring washer 14042 mates with and receives aportion of the tubular lower mandrel 14006 and an end face of the innerflange of the tubular spring washer is positioned proximate and end faceof the external flange 14006 d of the tubular lower mandrel. The tubularspring washer 14042 is further received within the longitudinal passage14034 a of the tubular spring housing 14034.

An end of a retracting spring 14044 that receives the tubular lowermandrel 14006 is positioned within the tubular spring washer 14042 incontact with the internal flange 14042 a of the tubular spring washerand the other end of the retracting spring is positioned in contact withan end face of the tubular retracting spring ring 14036.

A sealing element 14046 is received within the external annular recess14006 j of the tubular lower mandrel 14006 for sealing the interfacebetween the tubular lower mandrel and the tubular spring housing 14034.A sealing element 14048 is received within the internal annular recess14034 h of the tubular spring housing 14034 for sealing the interfacebetween the tubular spring housing and the tubular lower mandrel 14006.

An internal threaded connection 14050 a of an end of a tubular upperhinge sleeve 14050 that includes an internal flange 14050 b and aninternal pivot 14050 c receives and is coupled to the external threadedconnection 14034 i of the end of the tubular spring housing 14034.

An external flange 14052 a of a base member 14052 b of an upper camassembly 14052, that is mounted upon and receives the lower tubularmandrel 14006, that includes an internal flange 14052 c that is receivedwithin the external annular recess 14006 e of the lower tubular mandrel14006 and a plurality of circumferentially spaced apart cam arms 14052 dextending from the base member mates with and is received within thetubular upper hinge sleeve 14050. The base member 14052 b of the uppercam assembly 14052 further includes a plurality of circumferentiallyspaced apart teeth 14052 f that mate with and are received within aplurality of circumferentially spaced apart teeth 14034 j provided onthe end face of the tubular spring housing 14034 and an end face of theexternal flange 14052 a of the base member of the upper cam assembly ispositioned in opposing relation to an end face of the internal flange14050 b of the tubular upper hinge sleeve 14050. Each of the cam arms14052 d of the upper cam assembly 14052 include external cam surfaces14052 e. In an exemplary embodiment, the teeth 14052 f of the basemember 14052 b of the upper cam assembly 14052 and the teeth 14034 jprovided on the end face of the tubular spring housing 14034 permittorsional loads to be transmitted between the tubular spring housing andthe upper cam assembly.

A plurality of circumferentially spaced apart upper casing cuttersegments 14054 are mounted upon and receive the lower tubular mandrel14006 and each include an external pivot recess 14054 a for mating withand receiving the internal pivot 14050 c of the tubular upper hingesleeve 14050 and an external flange 14054 b and are pivotally mountedwithin the tubular upper hinge sleeve and are interleaved with thecircumferentially spaced apart cam arms 14052 d of the upper camassembly 14052. A casing cutter element 14056 is coupled to andsupported by the upper surface of each upper casing cutter segments14054 proximate the external flange 14054 b.

A plurality of circumferentially spaced apart lower casing cuttersegments 14058 are mounted upon and receive the lower tubular mandrel14006, are interleaved among the upper casing cutter segments 14054, areoriented in the opposite direction to the upper casing cutter segments14054, each include an external pivot recess 14058 a, and are positionedin opposing relation to corresponding circumferentially spaced apart camarms 14052 d of the upper cam assembly 14052.

A lower cam assembly 14060 is mounted upon and receives the lowertubular mandrel 14006 that includes a base member 14060 a having anexternal flange 14060 b, a plurality of circumferentially spaced apartcam arms 14060 d that extend from the base member that each includeexternal cam surfaces 14060 e and define mounting holes 14060 f and14060 g. The base member 14060 a of the lower cam assembly 14060 furtherincludes a plurality of circumferentially spaced apart teeth 14060 h.The circumferentially spaced apart cam arms 14060 d of the lower camassembly 14060 are interleaved among the lower casing cutter segments14058 and the circumferentially spaced apart cam arms 14052 d of theupper cam assembly 14052 and positioned in opposing relation tocorresponding upper casing cutter segments 14054.

Mounting screws, 14062 a, 14062 b, 14062 c, and 14062 e, are mountedwithin the corresponding mounting holes, 14060 f and 14060 g, of thelower cam assembly 14060 and are received within the external annularrecess 14006 g of the lower cam assembly 14060.

A tubular lower hinge sleeve 14064 that receives the lower casing cuttersegments 14058 and the lower cam assembly 14060 includes an internalflange 14064 a for engaging the external flange 14060 b of the basemember of the lower cam assembly 14060, an internal pivot 14064 b forengaging and receiving the external pivot recess 14058 a of the lowercasing cutter segments 14058 thereby pivotally mounting the lower casingcutter segments within the tubular lower hinge sleeve, and an internalthreaded connection 14064 c.

An external threaded connection 14066 a of an end of a tubular sleeve14066 that defines mounting holes, 14066 b and 14066 c, and includes aninternal annular recess 14066 d having a shoulder 14066 e, an internalflange 14066 f, and an internal threaded connection 14066 g at anotherend is received within and coupled to the internal threaded connection14064 c of the tubular lower hinge sleeve 14064. An external threadedconnection 14068 a of an end of a tubular member 14068 that defines alongitudinal passage 14068 b and mounting holes, 14068 c and 14068 d,and includes an external annular recess 14068 e, and an externalthreaded connection 14068 f at another end is received within and iscoupled to the internal threaded connection 14066 g of the tubularsleeve 14066.

Mounting screws, 14070 a and 14070 b, are mounted in and coupled to themounting holes, 14068 c and 14068 d, respectively, of the tubular member14068 that also extend into the mounting holes, 14066 b and 14066 c,respectively, of the tubular sleeve 14066. A sealing element 14072 isreceived within the external annular recess 14068 e of the tubularmember 14068 for sealing the interface between the tubular member andthe tubular sleeve 14066.

An internal threaded connection 14074 a of a tubular retracting piston14074 that defines a longitudinal passage 14074 b and includes aninternal annular recess 14074 c and an external annular recess 14074 dreceives and is coupled to the external threaded connection 14006 i ofthe tubular lower mandrel 14006. A sealing element 14076 is receivedwithin the external annular recess 14074 d of the tubular retractingpiston 14074 for sealing the interface between the tubular retractingpiston and the tubular sleeve 14066. A sealing element 14078 is receivedwithin the internal annular recess 14074 c of the tubular retractingpiston 14074 for sealing the interface between the tubular retractingpiston and the tubular lower mandrel 14006.

Locking dogs 14080 mate with and receive the external teeth 14006 h ofthe tubular lower mandrel 14006. A spacer ring 14082 is positionedbetween an end face of the locking dogs 14080 and an end face of thelower cam assembly 14060. A release piston 14084 mounted upon thetubular lower mandrel 14006 defines a radial passage 14084 a formounting a burst disk 14086 includes sealing elements, 14084 b, 14084 c,and 14084 d. The sealing elements, 14084 b and 14084 d, sealing theinterface between the release piston 14084 and the tubular lower mandrel14006. An end face of the release piston 14084 is positioned in opposingrelation to an end face of the locking dogs 14080.

A release sleeve 14088 that receives and is mounted upon the lockingdogs 14080 and the release piston 14084 includes an internal flange14088 a at one end that sealingly engages the tubular lower mandrel14006. A bypass sleeve 14090 that receives and is mounted upon therelease sleeve 14088 includes an internal flange 14090 a at one end.

In an exemplary embodiment, during operation of the casing cutterassembly 14, the retracting spring 14044 is compressed and therebyapplies a biasing spring force in a direction 14092 from the lowertubular mandrel 14006 to the tubular spring housing 14034 that, in theabsence of other forces, moves and/or maintains the upper cam assembly14052 and the upper casing cutter segments 14054 out of engagement withthe lower casing cutter segments 14058 and the lower cam assembly 14060.In an exemplary embodiment, during operation of the casing cutterassembly 14, an external threaded connection 12 a of an end of thetubular support member 12 is coupled to the internal threaded connection14002 d of the upper tubular tool joint 14002 and an internal threadedconnection 16 a of an end of the ball gripper assembly 16 is coupled tothe external threaded connection 14068 f of the tubular member 14068.

The upper cam assembly 14052 and the upper casing cutter segments 14054may be brought into engagement with the lower casing cutter segments14058 and the lower cam assembly 14060 by pressurizing an annulus 14094defined between the lower tubular mandrel 14006 and the tubular springhousing 14034. In particular, injection of fluidic materials into thecam cutter assembly 14 through the longitudinal passage 14006 b of thelower tubular mandrel 14006 and into the radial passage 14006 ba maypressurize the annulus 14094 thereby creating sufficient operatingpressure to generate a force in a direction 14096 sufficient to overcomethe biasing force of the retracting spring 14044. As a result, thespring housing 14034 may be displaced in the direction 14096 relative tothe lower tubular mandrel 14006 thereby displacing the tubular upperhinge sleeve 14050, upper cam assembly 14052, and upper casing cuttersegments 14054 in the direction 14096.

In an exemplary embodiment, as illustrated in FIGS. 11P, 11Q and 11R,the displacement of the upper cam assembly 14052 and upper casing cuttersegments 14054 in the direction 14096 will cause the lower casing cuttersegments 14058 to ride up the cam surfaces of the cam arms of the uppercam assembly 14052 while also pivoting about the lower tubular hingesegment 14064, and will also cause the upper casing cutter segments14054 to ride up the cam surfaces of the cam arms of the lower camassembly 14060 while also pivoting about the upper tubular hinge segment14050.

In an exemplary embodiment, during the operation of the casing cutterassembly 14, when the upper and lower casing cutter segments, 14054 and14058, brought into axial alignment in a radially expanded position, thecasing cutter elements of the casing cutter segments are brought intointimate contact with the interior surface of a pre-selected portion ofthe expandable wellbore casing 100. The casing cutter assembly 14 maythen be rotated to thereby cause the casing cutter elements to cutthrough the expandable wellbore casing. The portion of the expandablewellbore casing 100 cut away from the remaining portion on theexpandable wellbore casing may then be carried out of the wellbore 102with the cut away portion of the expandable wellbore casing supported bythe casing cutter elements.

In an exemplary embodiment, the upper cam assembly 14052 and the uppercasing cutter segments 14054 may be moved out of engagement with thelower casing cutter segments 14058 and the lower cam assembly 14060 byreducing the operating pressure within the annulus 14094.

In an alternative embodiment, as illustrated in FIGS. 11S1, 11T, 11U and11V, during operation of the casing cutter assembly 14, the upper camassembly 14052 and the upper casing cutter segments 14054 may also bemoved out of engagement with the lower casing cutter segments 14058 andthe lower cam assembly 14060 by sensing the operating pressure withinthe longitudinal passage 14006 b of the lower tubular mandrel 14006. Inparticular, as illustrated in FIG. 11T, if the operating pressure withinthe longitudinal passage 14006 b and radial passage 14006 bb of thelower tubular mandrel 14006 exceeds a predetermined value, the burstdisc 14086 will open the passage 14084 a thereby pressurizing theinterior of the tubular release sleeve 14088 thereby displacing thetubular release sleeve 14088 downwardly in a direction 14092 away fromengagement with the locking dogs 14080.

As a result, as illustrated in FIG. 11U, the locking dogs 14080 aredisplaced outwardly in the radial directed and thereby released fromengagement with the lower tubular mandrel 14006 thereby permitting thelower casing cutter segments 14058 and the lower cam assembly 14060 tobe displaced downwardly relative to the lower tubular mandrel.

As a result, as illustrated in FIG. 11V, the operating pressure withinthe lower tubular mandrel 14066 may then cause the lower tubular mandrelto be displaced downwardly in the direction 14094 relative to thetubular lower mandrel 14006 and the retracting piston 14074. As aresult, the lower tubular mandrel 14066, the lower casing cuttersegments 14058, the lower cam assembly 14060, and tubular lower hingesleeve 14064 are displaced downwardly in the direction 14094 relative tothe tubular spring housing 14034 thereby moving the lower casing cuttersegments 14058 and the lower cam assembly 14060 out of engagement withthe upper cam assembly 14052 and the upper casing cutter segments 14054.

In an exemplary embodiment, as illustrated in FIGS. 11W, 11X, and 11Y,during operation of the casing cutter assembly 14, the casing cutterassembly 14 senses the diameter of the expandable wellbore casing 100using the upper toggle links, 14022 and 14028, lower toggle links, 14024and 14030, and triggers, 14026 and 14032, and then prevents theengagement of the upper cam assembly 14052 and the upper casing cuttersegments 14054 with the lower casing cutter segments 14058 and the lowercam assembly 14060.

In particular, as illustrated in FIG. 11W, anytime the upper togglelinks, 14022 and 14028, and lower toggle links, 14024 and 14030, arepositioned within a portion of the expandable wellbore casing 100 thathas been radially expanded and plastically deformed by the system 10,the triggers, 14026 and 14032, will be pivoted by the engagement arms,14024 d and 14030 d, of the lower toggle links, 14024 and 14030, to aposition in which the triggers will no longer engage the internal flange14034 d of the end of the tubular spring housing 14034 therebypermitting the displacement of the tubular spring housing in thedirection 14096. As a result, the upper cam assembly 14052 and the uppercasing cutter segments 14054 can be brought into engagement with thelower casing cutter segments 14058 and the lower cam assembly 14060. Inan exemplary embodiment, the upper toggle links, 14022 and 14028, andthe lower toggle links, 14024 and 14030, are spring biased towards theposition illustrated in FIG. 11W.

Conversely, as illustrated in FIG. 11X, anytime the upper toggle links,14022 and 14028, and lower toggle links, 14024 and 14030, are positionedwithin a portion of the expandable wellbore casing 100 that has not beenradially expanded and plastically deformed by the system 10, thetriggers, 14026 and 14032, will be maintained in a position in which thetriggers will engage the internal flange 14034 d of the end of thetubular spring housing 14034 thereby preventing the displacement of thetubular spring housing in the direction 14096. As a result, the uppercam assembly 14052 and the upper casing cutter segments 14054 cannot bebrought into engagement with the lower casing cutter segments 14058 andthe lower cam assembly 14060. In an exemplary embodiment, the triggers,14026 and 14032, are spring biased towards the position illustrated inFIG. 11X.

In an exemplary embodiment, as illustrated in FIG. 11Y, the tubularspring housing 14034 may be displaced upwardly in the direction 14098even if the upper toggle links, 14022 and 14028, and lower toggle links,14024 and 14030, are positioned within a portion of the expandablewellbore casing 100 that has not been radially expanded and plasticallydeformed by the system 10.

In an exemplary embodiment, as illustrated in FIGS. 11Z1 to 11Z4, 11AA1to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE, the tubularspring housing 14034 of the casing cutter assembly 14 defines internalannular recesses 14034 k and 140341, spaced apart by an internal flange14034 m, the tubular toggle bushing 14008 defines an external annularrecess 14008 ac, and the casing cutter assembly further includes pins,14100 a and 14100 b and 14102 a and 14102 b, mounted in holes 14008 jand 14008 o and 14008 k and 14008 n, respectively, of the tubular togglebushing, and a one-shot deactivation device 14104 mounted on the tubulartoggle bushing between the pins, 14100 a and 14100 b and 14102 a and14102 b.

The one-shot deactivation device 14104 includes a tubular body 14104 athat defines radial holes, 14104 b and 14014 c, and includes an externalannular recess 14104 d at one end, a centrally positioned externalflange 14104 e, a centrally positioned internal annular recess 14104 f,and an external annular recess 14104 g at another end. An engagementmember 14106 that includes a base member 14106 a having a tapered end14106 b and a key member 14106 c having a tapered end 14106 d isreceived within a portion of the internal annular recess 14104 f of thetubular body 14104 a and an engagement member 14108 that includes a basemember 14108 a having a tapered end 14108 b and a key member 14108 chaving a tapered end 14108 d is received within an opposite portion ofthe internal annular recess 14104 f of the tubular body 14104 a. Springmembers, 14110 and 14112, are received within the annular recess 14104 fof the tubular body 14104 a for biasing the base members, base member14106 a and 14108 a, of the engagement members, 14106 and 14108,respectively, radially inwardly relative to the tubular body 14104 a.

In an exemplary embodiment, during operation of the casing cutterassembly 14, as illustrated in FIGS. 11Z1 to 11Z4, the one-shotdeactivation device 14104 are positioned proximate and in intimatecontact with the pins, 14102 a and 14102 b, with the tapered ends, 14106b and 14108 b, of the base members, 14106 a and 14108 a, of theengagement members, 14106 and 14108, received within the externalannular recess 14008 ac of the tubular toggle bushing 14008. When theone-shot deactivation device 14104 is positioned as illustrated in FIG.11Z, the external annular recess 14104 d of the tubular body 14104 a ofthe one-shot deactivation device is moved out of engagement with theengagement arms, 14026 d and 14032 d, of the triggers, 14026 and 14032,respectively. As a result, the triggers, 14026 and 14032, may operatenormally as described above with reference to FIGS. 11W, 11X, and 11Y.

Conversely, in an exemplary embodiment, during operation of the casingcutter assembly 14, as illustrated in FIGS. 11AA1 to 11AA4, the one-shotdeactivation device 14104 are positioned proximate and in intimatecontact with the pins, 14100 a and 14100 b, with the tapered ends, 14106b and 14108 b, of the base members, 14106 a and 14108 a, of theengagement members, 14106 and 14108, not received within the externalannular recess 14008 ac of the tubular toggle bushing 14008. When theone-shot deactivation device 14104 is positioned as illustrated in FIGS.11AA1 to 11AA4, the external annular recess 14104 d of the tubular body14104 a of the one-shot deactivation device is moved into engagementwith the engagement arms, 14026 d and 14032 d, of the triggers, 14026and 14032, respectively. As a result, the triggers, 14026 and 14032, aredeactivated and may not operate normally as described above withreference to FIGS. 11W, 11X, and 11Y.

In an alternative embodiment, the elements of the casing cutter assembly14 that sense the diameter of the expandable wellbore casing 100 may bedisabled or omitted or adjusted to sense any pre-selected internaldiameter of the expandable wellbore casing.

In an exemplary embodiment, the ball gripper assembly 16 is provided andoperates substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application serial number PCT/US03/29859,filed on Sep. 22, 2003, (2) PCT patent application serial numberPCT/US03/14153, filed on Nov. 13, 2003, and/or (3) PCT patentapplication serial number PCT/US04/07711, filed on Mar. 11, 2004, and/or(4) PCT patent application serial number PCT/US04/09434, filed on Mar.26, 2004, and/or (5) PCT patent application serial numberPCT/US04/10317, filed on Apr. 2, 2004, and/or (6) PCT patent applicationserial number PCT/US04/10712, filed on Apr. 7, 2004, and/or (7) PCTpatent application serial number PCT/US04/10762, filed on Apr. 6, 2004,the disclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 12A1 to 12A4, 12Band 12C1 to 12C4, the ball gripper assembly 16 includes an upper mandrel1602 that defines a longitudinal passage 1602 a and a radial passage1602 b and includes an internal threaded connection 1602 c at one end,an external flange 1602 d at an intermediate portion that includes anexternal annular recess 1602 e having a shoulder 1602 f and an externalradial hole 1602 g, an external annular recess 1602 h, an externalannular recess 1602 i, an external annular recess 1602 j having atapered end 1602 k including an external annular recess 1602 ka, anexternal annular recess 1602 l, and an external annular recess 1602 m,and an external annular recess 1602 n, an external radial hole 1602 o,an external annular recess 1602 p, and an external annular recess 1602 qat another end.

An upper tubular bushing 1604 defines an internally threaded radialopening 1604 a and includes an external flange 1604 b having an externalannular recess 1604 c and an internal annular recess 1604 d mates withand receives the external flange 1602 d of the upper mandrel 1602. Inparticular, the internal annular recess 1604 d of the upper tubularbushing 1604 mates with the shoulder 1602 f of the external annularrecess 1602 e of the upper mandrel 1602. A screw 1606 that is threadablycoupled to the internally threaded radial opening 1604 a of the uppertubular bushing 1604 extends into the external radial hole 1602 g of theexternal flange 1602 d of the upper mandrel 1602.

A deactivation tubular sleeve 1608 defines a radial passage 1608 a andincludes an internal annular recess 1608 b that mates with and receivesan end of the external annular recess 1604 c of the external flange 1604b of the upper tubular bushing 1604, an internal annular recess 1608 cthat mates with and receives the external flange 1602 d of the uppermandrel 1602, an internal annular recess 1608 d, an internal annularrecess 1608 e, and an internal annular recess 1608 f. A deactivationspring 1610 is received within an annulus 1612 defined between theinternal annular recess 1608 b of the deactivation tubular sleeve 1608,an end face of the external annular recess 1604 c of the external flange1604 b of the upper tubular bushing 1604, and the external annularrecess 1602 h of the external flange 1602 d of the upper mandrel 1602.

A sealing member 1614 is received with the external annular recess 1602i of the external flange 1602 d of the upper mandrel 1602 for sealingthe interface between the upper mandrel and the deactivation tubularsleeve 1608. An annular spacer element 1616 is received within theexternal annular recess 1602 ka of the tapered end 1602 k of theexternal annular recess 1602 l of the upper mandrel 1602.

One or more inner engagement elements 1618 a of a tubular coglet 1618engage and are received within the external annular recess 1602 ka ofthe tapered end 1602 k of the external annular recess 1602 j of theupper mandrel 1602 and one or more outer engagement elements 1618 b ofthe coglet engage and are received within the internal annular recess1608 d of the deactivation tubular sleeve 1608.

An external annular recess 1620 a of an end of a tubular coglet prop1620 that includes an inner flange 1620 b receives and mates with theinner surfaces of the outer engagement elements 1618 b of the coglet1618. The end of the tubular coglet prop 1620 further receives and mateswith the external annular recess 1602 j of the external flange 1602 d ofthe upper mandrel 1602. A sealing element 1622 is received within theexternal annular recess 16021 of the upper mandrel 1602 for sealing theinterface between the upper mandrel and the tubular coglet prop 1620.

An end of a tubular bumper sleeve 1624 that includes internal andexternal flanges, 1624 a and 1624 b, and a hole 1624 c at another endmates with and receives the external annular recess 1602 m of theexternal flange 1602 d of the upper mandrel 1602. A coglet spring 1626is received within an annulus 1628 defined between the external annularrecess 1602 m of the external flange 1602 d of the upper mandrel 1602,the tubular coglet prop 1620, the inner flange 1620 b of the tubularcoglet prop, an end face of the tubular bumper sleeve 1624, and theinternal annular recess 1608 c of the deactivation tubular sleeve 1608.

A tubular ball race 1628 that defines a plurality of tapered annularrecesses 1628 a and an internally threaded radial opening 1628 b andincludes one or more axial engagement elements 1628 c at one end and oneor more axial engagement elements 1628 d at another end receives andmates with the other end of the upper mandrel 1602. In an exemplaryembodiment, the axial engagement elements 1628 c of the tubular ballrace 1628 are received within and are coupled to the hole 1624 c of thetubular bumper sleeve 1624. An end of a tubular activation sleeve 1630that defines a plurality of radial openings 1630 a, a radial opening1630 b, a radial opening 1630 c, and includes an internal annular recess1630 d receives and mates with the tubular ball race 1628. In anexemplary embodiment, an end face of an end of the tubular activationsleeve 1630 is positioned proximate and in opposing relation to an endface of an end of the deactivation sleeve 1608. In an exemplaryembodiment, the radial openings 1630 a are aligned with and positionedin opposing relation to corresponding of tapered annular recesses 1628 aof the tubular ball race 1628, and the radial openings are also narrowedin cross section in the radial direction for reasons to be described.

Balls 1632 are received within each of the of tapered annular recesses1628 a and corresponding radial openings 1630 a of the tubular ball race1628 and tubular activation sleeve 1630, respectively. In an exemplaryembodiment, the narrowed cross sections of the radial openings 1630 a ofthe tubular activation sleeve 1630 will permit the balls 1632 to bedisplaced outwardly in the radial direction until at least a portion ofthe balls extends beyond the outer perimeter of the tubular activationsleeve to thereby permit engagement of the balls with an outer structuresuch as, for example, a wellbore casing.

A lower mandrel 1634 that defines a longitudinal passage 1634 a and aninternally threaded radial passage 1634 b at one end and includesinternal annular recesses, 1634 c and 1634 d, for receiving and matingwith the external annular recesses, 1602 p and 1602 q, of the uppermandrel 1602, an internal annular recess 1634 e, an external flange 1634f, and an externally threaded connection 1634 g at another end. In anexemplary embodiment, as illustrated in FIG. 12B, the end of the lowermandrel 1634 further includes longitudinal recesses 1634 h for receivingand mating with corresponding axial engagement elements 1628 d of thetubular ball race 1628. A sealing element 1635 is received within theinternal annular recess 1634 d of the lower mandrel 1634 for sealing aninterface between the lower mandrel and the external annular recess 1602p of the upper mandrel 1602.

A tubular spring retainer 1636 that defines a radial passage 1636 a andincludes an external annular recess 1636 b at one end mates with andreceives the end of the lower mandrel 1634 and is positioned proximatean end face of the external flange 1634 f of the lower mandrel. Atubular spring retainer 1638 receives and mates with the end of thelower mandrel 1634 and is received and mates with the internal annularrecess 1630 d of the tubular activation sleeve 1630.

An activation spring 1640 is received within an annulus 1642 defined anend face of the tubular spring retainer 1638, an end face of the springretainer 1636, the internal annular recess 1630 d of the tubularactivation sleeve 1630, and the end of the lower mandrel 1634. Aretainer screw 1642 is received within and is threadably coupled to theinternally threaded radial opening 1634 b of the lower mandrel 1634 thatalso extends into the external radial hole 1602 o of the upper mandrel1602.

During operation of the ball gripper assembly 16, in an exemplaryembodiment, as illustrated in FIGS. 12A1 to 12A4, the ball gripperassembly may be positioned within the expandable wellbore casing 100 andthe internally threaded connection 1602 c of the upper mandrel 1602 maybe coupled to an externally threaded connection 14 a of an end of thecasing cutter assembly 14 and the externally threaded connection 1634 gof the lower mandrel 1634 may be coupled to an internally threadedconnection 18 a of an end of the tension actuator assembly 18.

In an alternative embodiment, the internally threaded connection 1602 cof the upper mandrel 1602 may be coupled to an externally threadedconnection of an end of the tension actuator assembly 18 and theexternally threaded connection 1634 g of the lower mandrel 1634 may becoupled to an internally threaded connection of an end of casing cutterassembly 14.

In an exemplary embodiment, the deactivation spring 1610 has a greaterspring rate than the activation spring 1640. As a result, in an initialoperating mode, as illustrated in FIGS. 12A1 to 12A4, a biasing springforce is applied to the deactivation sleeve 1608 and activation sleeve1630 in a direction 1644 that maintains the activation sleeve in aposition relative to the tubular ball race 1628 that maintains the balls1632 within the radially inward portions of the corresponding taperedannular recesses 1628 a of the tubular ball race such that the balls donot extend beyond the perimeter of the activation sleeve to engage theexpandable wellbore casing 100.

As illustrated in FIGS. 12C1 to 12C4, in an exemplary embodiment, theball gripper 16 may be operated to engage the interior surface of theexpandable wellbore casing 100 by injecting a fluidic material 1650 intothe ball gripper assembly through the longitudinal passages 1602 a and1634 aa, of the upper and lower mandrels, 1602 and 1634, respectively.

In particular, when the longitudinal and radial passages, 1602 a and1602 b, respectively, of the upper mandrel 1602 are pressurized by theinjection of the fluidic material 1650, the internal annular recess 1608c of the deactivation tubular sleeve 1608 is pressurized. When theoperating pressure of the fluidic material 1650 within the internalannular recess 1608 c of the deactivation tubular sleeve 1608 issufficient to overcome the biasing spring force of the deactivationspring 1610, the deactivation tubular sleeve is displaced in a direction1652. As a result, the spring force provided by the activation spring1640 then may displace the activation tubular sleeve 1630 in thedirection 1652 thereby moving the balls 1632 on the correspondingtapered annular recesses 1628 a of the tubular ball race 1628 outwardlyin a radial direction into engagement with the interior surface of theexpandable wellbore casing 100. In an exemplary embodiment, theoperating pressure of the fluidic material 1650 sufficient to overcomethe biasing spring force of the deactivation spring 1610 was about 100psi.

In an exemplary embodiment, when the operating pressure of the fluidicmaterial 1650 is reduced, the operating pressure of the fluidic material1650 within the internal annular recess 1608 c of the deactivationtubular sleeve 1608 is no longer sufficient to overcome the biasingspring force of the deactivation spring 1610, and the deactivationtubular sleeve and the activation tubular sleeve 1630 are displaced in adirection opposite to the direction 1652 thereby moving the balls 1632radially inwardly and out of engagement with the interior surface of theexpandable wellbore casing 100.

In an exemplary embodiment, the ball gripper assembly 16 is operated toengage the interior surface of the expandable wellbore casing 100 incombination with the operation of the tension actuator assembly 18 toapply an upward tensile force to one or more elements of the system 10coupled to and positioned below the tension actuator assembly. As aresult, a reaction force comprising a downward tensile force is appliedto the lower mandrel 1634 of the ball gripper assembly 16 in a directionopposite to the direction 1652 during the operation of the tensionactuator assembly 18. Consequently, due to the geometry of the tapered1628 a of the tubular ball race 1628, the balls 1632 are driven up thetapered annular recesses 1628 a of the tubular ball race 1628 withincreased force and the contact force between the balls 1632 and theinterior surface of the expandable wellbore casing 100 is significantlyincreased thereby correspondingly increasing the gripping force andeffect of the ball gripper assembly.

In an exemplary embodiment, the ball gripper assembly 16 may be operatedto radially expand and plastically deform discrete portions of theexpandable wellbore casing 100 by controlling the amount of contactforce applied to the interior surface of the expandable wellbore casingby the balls 1632 of the ball gripper assembly. In an experimental testof an exemplary embodiment of the ball gripper assembly 16, anexpandable wellbore casing was radially expanded and plasticallydeformed. This was an unexpected result.

In an exemplary embodiment, the tension actuator assembly 18 operatesand is provided substantially, at least in part, as disclosed in one ormore of the following: (1) PCT patent application serial numberPCT/US02/36267, filed on Nov. 12, 2002, and/or (2) PCT patentapplication serial number PCT/US03/29859, filed on Sep. 22, 2003, and/or(3) PCT patent application serial number PCT/US03/14153, filed on Nov.13, 2003, and/or (4) PCT patent application serial numberPCT/US03/29460, filed on Sep. 23, 2003, and/or (5) PCT patentapplication serial number PCT/US04/07711, filed on Mar. 11, 2004, and/or(6) PCT patent application serial number PCT/US04/09434, filed on Mar.26, 2004, and/or (7) PCT patent application serial numberPCT/US04/10317, filed on Apr. 2, 2004, and/or (8) PCT patent applicationserial number PCT/US04/10712, filed on Apr. 7, 2004, and/or (9) PCTpatent application serial number PCT/US04/10762, filed on Apr. 6, 2004,the disclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8 and13B1 to 13B7, the tension actuator assembly 18 includes an upper tubularsupport member 18002 that defines a longitudinal passage 18002 a, andexternal internally threaded radial openings, 18002 b and 18002 c, andan external annular recess 18002 d and includes an internally threadedconnection 18002 e at one end and an external flange 18002 f, anexternal annular recess 18002 g having an externally threadedconnection, and an internal annular recess 18002 h having an internallythreaded connection at another end. An end of a tubular actuator barrel18004 that defines radial passages, 18004 a and 18004 b, at one end andradial passages, 18004 c and 18004 d, includes an internally threadedconnection 18004 e at one end that mates with, receives, and isthreadably coupled to the external annular recess 18002 g of the uppertubular support member 18002 and abuts and end face of the externalflange 18002 f of the upper tubular support member and an internallythreaded connection 18004 f at another end.

Torsional locking pins, 18006 a and 18006 b, are coupled to and mountedwithin the external radial mounting holes, 18002 b and 18002 c,respectively, of the upper tubular support member and received withinthe radial passages, 18004 a and 18004 b, of the end of the tubularactuator barrel 18004. The other end of the tubular actuator barrel18004 receives and is threadably coupled to an end of a tubular barrelconnector 18008 that defines an internal annular recess 18008 a,external radial mounting holes, 18008 b and 18008 c, radial passages,18008 d and 18008 e, and external radial mounting holes, 18008 f and18008 g and includes circumferentially spaced apart teeth 18008 h at oneend. A sealing cartridge 18010 is received within and coupled to theinternal annular recess 18008 a of the tubular barrel connector 18008for fluidicly sealing the interface between the tubular barrel connectorand the sealing cartridge. Torsional locking pins, 18012 a and 18012 b,are coupled to and mounted within the external radial mounting holes,18008 b and 18008 c, respectively, of the tubular barrel connector 18008and received within the radial passages, 18004 c and 18004 d, of thetubular actuator barrel 18004.

A tubular member 18014 that defines a longitudinal passage 18014 ahaving one or more internal splines 18014 b at one end andcircumferentially spaced apart teeth 18014 c at another end for engagingthe circumferentially spaced apart teeth 18008 h of the tubular barrelconnector 18008 mates with and is received within the actuator barrel18004 and the one end of the tubular member abuts an end face of theother end of the upper tubular support member 18002 and at another endabuts and end face of the tubular barrel connector 18008. A tubularguide member 18016 that defines a longitudinal passage 18016 a having atapered opening 18016 aa, and radial passages, 18016 b and 18016 c,includes an external flange 18016 d having an externally threadedconnection at one end that is received within and coupled to theinternal annular recess 18002 h of the upper tubular support member18002.

The other end of the tubular barrel connector 18008 is threadablycoupled to and is received within an end of a tubular actuator barrel18018 that defines a longitudinal passage 18018 a, radial passages,18018 b and 18018 c, and radial passages, 18018 d and 18018 e. Torsionallocking pins, 18020 a and 18020 b, are coupled to and mounted within theexternal radial mounting holes, 18008 f and 18008 g, respectively, ofthe tubular barrel connector 18008 and received within the radialpassages, 18018 b and 18018 c, of the tubular actuator barrel 18018. Theother end of the tubular actuator barrel 18018 receives and isthreadably coupled to an end of a tubular barrel connector 18022 thatdefines an internal annular recess 18022 a, external radial mountingholes, 18022 b and 18022 c, radial passages, 18022 d and 18022 e, andexternal radial mounting holes, 18022 f and 18022 g. A sealing cartridge18024 is received within and coupled to the internal annular recess18022 a of the tubular barrel connector 18022 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 18024 a and 18024 b, are coupled toand mounted within the external radial mounting holes, 18022 b and 18022c, respectively, of the barrel connector 18022 and received within theradial passages, 18018 d and 18018 e, of the tubular actuator barrel18018.

The other end of the tubular barrel connector 18022 is threadablycoupled to and is received within an end of a tubular actuator barrel18026 that defines a longitudinal passage 18026 a, radial passages,18026 b and 18026 c, and radial passages, 18026 d and 18026 e. Torsionallocking pins, 18028 a and 18028 b, are coupled to and mounted within theexternal radial mounting holes, 18022 f and 18022 g, respectively, ofthe tubular barrel connector 18022 and received within the radialpassages, 18026 b and 18026 c, of the tubular actuator barrel 18026. Theother end of the tubular actuator barrel 18026 receives and isthreadably coupled to an end of a tubular barrel connector 18030 thatdefines an internal annular recess 18030 a, external radial mountingholes, 18030 b and 18030 c, radial passages, 18030 d and 18030 e, andexternal radial mounting holes, 18030 f and 18030 g. A sealing cartridge18032 is received within and coupled to the internal annular recess18030 a of the tubular barrel connector 18030 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 18034 a and 18034 b, are coupled toand mounted within the external radial mounting holes, 18030 b and 18030c, respectively, of the tubular barrel connector 18030 and receivedwithin the radial passages, 18026 d and 18026 e, of the tubular actuatorbarrel 18026.

The other end of the tubular barrel connector 18030 is threadablycoupled to and is received within an end of a tubular actuator barrel18036 that defines a longitudinal passage 18036 a, radial passages,18036 b and 18036 c, and radial passages, 18036 d and 18036 e. Torsionallocking pins, 18038 a and 18038 b, are coupled to and mounted within theexternal radial mounting holes, 18030 f and 18030 g, respectively, ofthe tubular barrel connector 18030 and received within the radialpassages, 18036 b and 18036 c, of the tubular actuator barrel 18036. Theother end of the tubular actuator barrel 18036 receives and isthreadably coupled to an end of a tubular barrel connector 18040 thatdefines an internal annular recess 18040 a, external radial mountingholes, 18040 b and 18040 c, radial passages, 18040 d and 18040 e, andexternal radial mounting holes, 18040 f and 18040 g. A sealing cartridge18042 is received within and coupled to the internal annular recess18040 a of the tubular barrel connector 18040 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 18044 a and 18044 b, are coupled toand mounted within the external radial mounting holes, 18040 b and 18040c, respectively, of the tubular barrel connector 18040 and receivedwithin the radial passages, 18036 d and 18036 e, of the tubular actuatorbarrel 18036.

The other end of the tubular barrel connector 18040 is threadablycoupled to and is received within an end of a tubular actuator barrel18046 that defines a longitudinal passage 18046 a, radial passages,18046 b and 18046 c, and radial passages, 18046 d and 18046 e. Torsionallocking pins, 18048 a and 18048 b, are coupled to and mounted within theexternal radial mounting holes, 18040 f and 18040 g, respectively, ofthe tubular barrel connector 18040 and received within the radialpassages, 18046 b and 18046 c, of the tubular actuator barrel 18046. Theother end of the tubular actuator barrel 18046 receives and isthreadably coupled to an end of a tubular barrel connector 18050 thatdefines an internal annular recess 18050 a, external radial mountingholes, 18050 b and 18050 c, radial passages, 18050 d and 18050 e, andexternal radial mounting holes, 18050 f and 18050 g. A sealing cartridge18052 is received within and coupled to the internal annular recess18050 a of the tubular barrel connector 18050 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 18054 a and 18054 b, are coupled toand mounted within the external radial mounting holes, 18050 b and 18050c, respectively, of the tubular barrel connector 18050 and receivedwithin the radial passages, 18046 d and 18046 e, of the tubular actuatorbarrel 18046.

The other end of the tubular barrel connector 18050 is threadablycoupled to and is received within an end of a tubular actuator barrel18056 that defines a longitudinal passage 18056 a, radial passages,18056 b and 18056 c, and radial passages, 18056 d and 18056 e. Torsionallocking pins, 18058 a and 18058 b, are coupled to and mounted within theexternal radial mounting holes, 18050 f and 18050 g, respectively, ofthe tubular barrel connector 18050 and received within the radialpassages, 18056 b and 18056 c, of the tubular actuator barrel 18056. Theother end of the tubular actuator barrel 18056 receives and isthreadably coupled to an end of a tubular lower stop 18060 that definesan internal annular recess 18060 a, external radial mounting holes,18060 b and 18060 c, and an internal annular recess 18060 d thatincludes one or more circumferentially spaced apart locking teeth 18060e at one end and one or more circumferentially spaced apart lockingteeth 18060 f at the other end. A sealing cartridge 18062 is receivedwithin and coupled to the internal annular recess 18060 a of the tubularlower stop 18060 for fluidicly sealing the interface between the tubularlower stop and the sealing cartridge. Torsional locking pins, 18064 aand 18064 b, are coupled to and mounted within the external radialmounting holes, 18060 b and 18060 c, respectively, of the tubular lowerstop 18060 and received within the radial passages, 18056 d and 18056 e,of the tubular actuator barrel 18056.

A connector tube 18066 that defines a longitudinal passage 18066 a andradial mounting holes, 18066 b and 18066 c, and includes externalsplines 18066 d at one end for engaging the internal splines 18014 b ofthe tubular member 18014 and radial mounting holes, 18066 e and 18066 f,at another end is received within and sealingly and movably engages theinterior surface of the sealing cartridge 18010 mounted within theannular recess 18008 a of the tubular barrel connector 18008. In thismanner, during longitudinal displacement of the connector tube 18066relative to the tubular barrel connector 18008, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the tubular barrel connector. An end of theconnector tube 18066 also receives and mates with the other end of thetubular guide member 18016. Mounting screws, 18068 a and 18068 b, arecoupled to and received within the radial mounting holes, 18066 b and18066 c, respectively of the connector tube 18066.

The other end of the connector tube 18066 is received within andthreadably coupled to an end of a tubular piston 18070 that defines alongitudinal passage 18070 a, radial mounting holes, 18070 b and 18070c, radial passages, 18070 d and 18070 e, and radial mounting holes,18070 f and 18070 g, that includes a flange 18070 h at one end. Asealing cartridge 18072 is mounted onto and sealingly coupled to theexterior of the tubular piston 18070 proximate the flange 18070 h. Thesealing cartridge 18072 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 18018. In this manner,during longitudinal displacement of the tubular piston 18070 relative tothe actuator barrel 18018, a fluidic seal is maintained between theexterior surface of the piston and the interior surface of the actuatorbarrel. Mounting screws, 18074 a and 18074 b, are coupled to and mountedwithin the external radial mounting holes, 18070 b and 18070 c,respectively, of the tubular piston 18070 and received within the radialpassages, 18066 e and 18066 f, of the connector tube 18066.

The other end of the tubular piston 18070 receives and is threadablycoupled to an end of a connector tube 18076 that defines a longitudinalpassage 18076 a, radial mounting holes, 18076 b and 18076 c, at one endand radial mounting holes, 18076 d and 18076 e, at another end. Theconnector tube 18076 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 18024 mountedwithin the annular recess 18022 a of the tubular barrel connector 18022.In this manner, during longitudinal displacement of the connector tube18076 relative to the tubular barrel connector 18022, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 18078 a and18078 b, are coupled to and mounted within the external radial mountingholes, 18070 f and 18070 g, respectively, of the tubular piston 18070and received within the radial passages, 18076 b and 18076 c, of theconnector tube 18076.

The other end of the connector tube 18076 is received within andthreadably coupled to an end of a tubular piston 18080 that defines alongitudinal passage 18080 a, radial mounting holes, 18080 b and 18080c, radial passages, 18080 d and 18080 e, and radial mounting holes,18080 f and 18080 g, that includes a flange 18080 h at one end. Asealing cartridge 18082 is mounted onto and sealingly coupled to theexterior of the tubular piston 18080 proximate the flange 18080 h. Thesealing cartridge 18082 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 18026. In this manner,during longitudinal displacement of the tubular piston 18080 relative tothe tubular actuator barrel 18026, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 18084 a and 18084 b, are coupled toand mounted within the external radial mounting holes, 18080 b and 18080c, respectively, of the tubular piston 18080 and received within theradial passages, 18076 e and 18076 f, of the connector tube 18076.

The other end of the tubular piston 18080 receives and is threadablycoupled to an end of a connector tube 18086 that defines a longitudinalpassage 18086 a, radial mounting holes, 18086 b and 18086 c, at one endand radial mounting holes, 18086 d and 18086 e, at another end. Theconnector tube 18086 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 18032 mountedwithin the annular recess 18030 a of the tubular barrel connector 18030.In this manner, during longitudinal displacement of the connector tube18086 relative to the tubular barrel connector 18030, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 18088 a and18088 b, are coupled to and mounted within the external radial mountingholes, 18080 f and 18080 g, respectively, of the tubular piston 18080and received within the radial passages, 18086 b and 18086 c, of theconnector tube 18086.

The other end of the connector tube 18086 is received within andthreadably coupled to an end of a tubular piston 18090 that defines alongitudinal passage 18090 a, radial mounting holes, 18090 b and 18090c, radial passages, 18090 d and 18090 e, and radial mounting holes,18090 f and 18090 g, that includes a flange 18090 h at one end. Asealing cartridge 18092 is mounted onto and sealingly coupled to theexterior of the tubular piston 18090 proximate the flange 18090 h. Thesealing cartridge 18092 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 18036. In this manner,during longitudinal displacement of the tubular piston 18090 relative tothe tubular actuator barrel 18036, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 18094 a and 18094 b, are coupled toand mounted within the external radial mounting holes, 18090 b and 18090c, respectively, of the tubular piston 18090 and received within theradial passages, 18086 e and 18086 f, of the connector tube 18086.

The other end of the tubular piston 18090 receives and is threadablycoupled to an end of a connector tube 18096 that defines a longitudinalpassage 18096 a, radial mounting holes, 18096 b and 18096 c, at one endand radial mounting holes, 18096 d and 18096 e, at another end. Theconnector tube 18096 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 18042 mountedwithin the annular recess 18040 a of the tubular barrel connector 18040.In this manner, during longitudinal displacement of the connector tube18096 relative to the tubular barrel connector 18040, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 18098 a and18098 b, are coupled to and mounted within the external radial mountingholes, 18090 f and 18090 g, respectively, of the tubular piston 18090and received within the radial passages, 18096 b and 18096 c, of theconnector tube 18096.

The other end of the connector tube 18096 is received within andthreadably coupled to an end of a tubular piston 18100 that defines alongitudinal passage 18100 a, radial mounting holes, 18100 b and 18100c, radial passages, 18100 d and 18100 e, and radial mounting holes,18100 f and 18100 g, that includes a flange 18100 h at one end. Asealing cartridge 18102 is mounted onto and sealingly coupled to theexterior of the tubular piston 18100 proximate the flange 18100 h. Thesealing cartridge 18102 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 18046. In this manner,during longitudinal displacement of the tubular piston 18100 relative tothe tubular actuator barrel 18046, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 18104 a and 18104 b, are coupled toand mounted within the external radial mounting holes, 18100 b and 18100c, respectively, of the tubular piston 18100 and received within theradial passages, 18096 e and 18096 f, of the connector tube 18096.

The other end of the tubular piston 18100 receives and is threadablycoupled to an end of a connector tube 18106 that defines a longitudinalpassage 18106 a, radial mounting holes, 18106 b and 18106 c, at one endand radial mounting holes, 18106 d and 18106 e, at another end. Theconnector tube 18106 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 18052 mountedwithin the annular recess 18050 a of the tubular barrel connector 18050.In this manner, during longitudinal displacement of the connector tube18106 relative to the tubular barrel connector 18050, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 18108 a and18108 b, are coupled to and mounted within the external radial mountingholes, 18100 f and 18100 g, respectively, of the tubular piston 18100and received within the radial passages, 18106 b and 18106 c, of theconnector tube 18106.

The other end of the connector tube 18106 is received within andthreadably coupled to an end of a tubular piston 18110 that defines alongitudinal passage 18110 a, radial mounting holes, 18110 b and 18110c, radial passages, 18110 d and 18110 e, radial mounting holes, 18110 fand 18110 g, that includes a flange 18110 h at one end andcircumferentially spaced teeth 18110 i at another end for engaging theone or more circumferentially spaced apart locking teeth 18060 e of thetubular lower stop 18060. A sealing cartridge 18112 is mounted onto andsealingly coupled to the exterior of the tubular piston 18110 proximatethe flange 18110 h. The sealing cartridge 18112 also mates with andsealingly engages the interior surface of the actuator barrel 18056. Inthis manner, during longitudinal displacement of the tubular piston18110 relative to the actuator barrel 18056, a fluidic seal ismaintained between the exterior surface of the piston and the interiorsurface of the actuator barrel. Mounting screws, 18114 a and 18114 b,are coupled to and mounted within the external radial mounting holes,18110 b and 18110 c, respectively, of the tubular piston 18110 andreceived within the radial passages, 18106 d and 18106 e, of theconnector tube 18106.

The other end of the tubular piston 18110 receives and is threadablycoupled to an end of a connector tube 18116 that defines a longitudinalpassage 18116 a, radial mounting holes, 18116 b and 18116 c, at one endand radial mounting holes, 18116 d and 18116 e, at another end thatincludes an external flange 18116 f that includes circumferentiallyspaced apart teeth 18116 g that extend from an end face of the externalflange for engaging the teeth 18060 f of the tubular lower stop 18060,and an externally threaded connection 18116 h at another end. Theconnector tube 18116 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 18062 mountedwithin the annular recess 18060 a of the lower tubular stop 18060. Inthis manner, during longitudinal displacement of the connector tube18116 relative to the lower tubular stop 18060, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the lower tubular stop. Mounting screws, 18118 a and18118 b, are coupled to and mounted within the external radial mountingholes, 18110 f and 18110 g, respectively, of the tubular piston 18110and received within the radial passages, 18116 b and 18116 c, of theconnector tube 18116.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, theinternally threaded connection 18002 e of the upper tubular supportmember 18002 receives and is coupled to the externally threadedconnection 1234 g of the lower mandrel 1234 of the ball grabber assembly16 and the externally threaded connection 18116 h of the connector tube18116 is received within and is coupled to an internally threadedconnection 20 a of an end of the safety sub assembly 20.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, duringoperation of the tension actuator assembly 18, the tension actuatorassembly is positioned within the expandable wellbore casing 100 andfluidic material 18200 is injected into the tension actuator assemblythrough the passages 18002 a, 18016 a, 18066 a, 18070 a, 18076 a, 18080a, 18086 a, 18090 a, 18096 a, 18100 a, 18106 a, 18110 a, and 18116 a.The injected fluidic material 18200 will also pass through the radialpassages, 18070 d and 18070 e, 18080 d and 18080 e, 18090 d and 18090 e,18100 d and 18100 e, 18110 d and 18110 e, of the tubular pistons, 18070,18080, 18090, 18100, and 18110, respectively, into annular pistonchambers, 18202, 18204, 18206, 18208, 18208, and 18210.

As illustrated in FIGS. 13B1 to 13B7, the operating pressure of thefluidic material 18200 may then be increased by, for example,controllably blocking or limiting the flow of the fluidic materialthrough the passage 18116 a and/or increasing the operating pressure ofthe outlet of a pumping device for injecting the fluidic material 18200into the tension actuator assembly 18. As a result, of the increasedoperating pressure of the fluidic material 18200 within the tensionactuator assembly 18, the operating pressures of the annular pistonchambers, 18202, 18204, 18206, 18208, 18208, and 18210, will beincreased sufficiently to displace the tubular pistons, 18070, 18080,18090, 18100, and 18110, upwardly in the direction 18212 thereby alsodisplacing the connector tube 18116. As a result, a upward tensile forceis applied to all elements of the system 10 coupled to and positionedbelow the connector tube 18116. In an exemplary embodiment, during theupward displacement of the tubular pistons, 18070, 18080, 18090, 18100,and 18110, fluidic materials displaced by the tubular pistons withindischarge annular chambers, 18214, 18216, 18218, 18220, and 18222 areexhausted out of the tension actuator assembly 18 through the radialpassages, 18008 d and 18008 e, 18022 d and 18022 e, 18030 d and 18030 e,18040 d and 18040 e, 18050 d and 18050 e, respectively. Furthermore, inan exemplary embodiment, the upward displacement of the tubular pistons,18070, 18080, 18090, 18100, and 18110, further causes the externalsplines 18066 d of the connector tube 18066 to engage the internalsplines 18014 b of the tubular member 18014 and the circumferentiallyspaced apart teeth 18116 g of the connector tube 18116 to engage thecircumferentially spaced teeth 18060 f of the tubular lower stop 18060.As a result of the interaction of the external splines 18066 d of theconnector tube 18066 to engage the internal splines 18014 b of thetubular member 18014 and the circumferentially spaced apart teeth 18116g of the connector tube 18116 to engage the circumferentially spacedteeth 18060 f of the tubular lower stop 18060, torsional loads may betransmitted through the tension actuator assembly 18.

In an exemplary embodiment, as illustrated in FIG. 14A, the safety subassembly 20 includes a tubular body 200 a that defines a longitudinalpassage 200 b and includes an external flange 200 c and an internalannular recess 200 d at one end, and external annular recesses, 200 e,200 f, 200 g, and 200 h at another end. A sealing member 202 ispositioned within the external annular recess 200 h at the other end ofthe tubular body 200 a.

In an exemplary embodiment, as illustrated in FIGS. 14A, 14B and 14C,the sealing cup assembly 22 includes an upper tubular mandrel 2202 thatdefines a longitudinal passage 2202 a and internally threaded radialmounting holes, 2202 b and 2202 c, and includes an internal annularrecess 2202 d at one end, an internal annular recess 2202 e, an internalannular recess 2202 f, an internal annular recess 2202 g, and aninternally threaded internal annular recess 2202 h and an externalflange 2202 i at another end. The internal annular recesses, 2202 d,2202 e, and 2202 f, of the upper tubular mandrel 2202 of the sealing cupassembly 22 receive, mate with, and are coupled to the other end of thetubular body 200 a of the safety sub assembly 20.

An externally threaded end of a lower tubular mandrel 2204 that definesa longitudinal passage 2204 a and includes an external annular recess2204 b at one end, an external annular recess 2204 c, an external flange2204 d, an external annular recess 2204 e, an externally threadedexternal flange 2204 f, and an external annular recess 2204 g at anotherend mates with, is received within, and is coupled to the internalannular recesses, 2202 g and 2202 h, of the other end of the uppertubular mandrel 2202.

Mounting screws, 2250 a and 2205 b, are received within and coupled tothe mounting holes, 2202 c and 2202 b, respectively, of the tubularmandrel 2202 that extend into and engage the external annular recess2204 c of the lower tubular mandrel 2204.

A tubular cup seal spacer 2206 receives and is mounted upon the lowertubular mandrel 2204 proximate the external flange 2202 i of the uppertubular mandrel 2202. A tubular cup seal retainer 2208 that includes aninternal flange 2208 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the tubular cup seal spacer 2206. Atubular cup seal retainer 2210 that includes an internal flange 2210 aat one end receives and is mounted upon the lower tubular mandrel 2204proximate the other end of the tubular cup seal retainer 2208. In anexemplary embodiment, the tubular cup seal retainer 2210 is nestedwithin the other end of the tubular cup seal retainer 2208. A tubularcup seal 2212 that includes an internal flange 2212 a at one endreceives and is mounted upon the lower tubular mandrel 2204 proximatethe other end of the tubular cup seal retainer 2210. In an exemplaryembodiment, the tubular cup seal 2212 is nested within the other end ofthe tubular cup seal retainer 2210.

A sealing member 2211 is received within the external annular recess2204 b of the lower tubular mandrel 2204 for sealing the interfacebetween the lower tubular mandrel and the upper tubular mandrel 2202.

A tubular spacer 2214 receives and is mounted upon the lower tubularmandrel 2204 proximate the other end of the tubular cup seal 2212.

A tubular cup seal spacer 2216 receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubular spacer 2214.A tubular cup seal retainer 2218 that includes an internal flange 2218 aat one end receives and is mounted upon the lower tubular mandrel 2204proximate the other end of the tubular cup seal spacer 2216. A tubularcup seal retainer 2220 that includes an internal flange 2220 a at oneend receives and is mounted upon the lower tubular mandrel 2204proximate the other end of the tubular cup seal retainer 2218. In anexemplary embodiment, the tubular cup seal retainer 2220 is nestedwithin the other end of the tubular cup seal retainer 2218. A tubularcup seal 2222 that includes an internal flange 2222 a at one endreceives and is mounted upon the lower tubular mandrel 2204 proximatethe other end of the tubular cup seal retainer 2220. In an exemplaryembodiment, the tubular cup seal 2222 is nested within the other end ofthe tubular cup seal retainer 2220.

A tubular spacer 2224 receives and is mounted upon the lower tubularmandrel 2204 proximate the other end of the tubular cup seal 2222 at oneend and proximate the external flange 2204 d of the lower tubularmandrel at another end. A retaining ring 2226 receives and is mountedupon the other end of the tubular spacer 2224 proximate the externalflange 2204 d of the lower tubular mandrel 2204.

In an exemplary embodiment, during operation of the system 10, the endof the tubular body 200 a of the safety sub assembly 20 is coupled toand receives and is coupled to an end of the tension actuator assembly18 and the other end of the lower tubular mandrel 2204 of the sealingcup assembly 22 is received within and is coupled to an end of thecasing lock assembly 24.

In an exemplary embodiment, during operation of the system 10, thetubular cup seals, 2212 and/or 2222, sealingly engage the interiorsurface of the expandable tubular member 100. In this manner, when anannulus defined between the system 10 and the expandable wellbore casing10, below the tubular cup seals, 2212 and/or 2222, is pressurized, theresulting pressure differential across the tubular cup seals applies anupward tensile force to the system thereby pulling the adjustable bellsection expansion cone assembly 28 and/or the adjustable casingexpansion cone assembly 30 through the expandable wellbore casing. Inthis manner, the adjustable bell section expansion cone assembly 28and/or the adjustable casing expansion cone assembly 30, if either orboth are adjusted to an outside diameter suitable for a radial expansionoperation, may radially expand and plastically deform the expandablewellbore casing 100.

In an exemplary embodiment, the sealing cup assembly 22 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application serial number PCT/US02/36157,filed on Nov. 12, 2002, and/or (2) PCT patent application serial numberPCT/US02/36267, filed on Nov. 12, 2002, and/or (3) PCT patentapplication serial number PCT/US03/04837, filed on Feb. 29, 2003, and/or(4) PCT patent application serial number PCT/US03/29859, filed on Sep.22, 2003, and/or (5) PCT patent application serial numberPCT/US03/14153, filed on Nov. 13, 2003, and/or (6) PCT patentapplication serial number PCT/US03/18530, filed on Jun. 11, 2003, and/or(7) PCT patent application serial number PCT/US04/07711, filed on Mar.11, 2004, and/or (8) PCT patent application serial numberPCT/US04/09434, filed on Mar. 26, 2004, and/or (9) PCT patentapplication serial number PCT/US04/10317, filed on Apr. 2, 2004, and/or(10) PCT patent application serial number PCT/US04/10712, filed on Apr.7, 2004, and/or (11) PCT patent application serial numberPCT/US04/10762, filed on Apr. 6, 2004, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, the casing lock assembly 24 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application serial number PCT/US02/36267,filed on Nov. 12, 2002, and/or (2) PCT patent application serial numberPCT/US03/29859, filed on Sep. 22, 2003, and/or (3) PCT patentapplication serial number PCT/US03/14153, filed on Nov. 13, 2003, and/or(4) PCT patent application serial number PCT/US04/07711, filed on Mar.11, 2004, and/or (5) PCT patent application serial numberPCT/US04/09434, filed on Mar. 26, 2004, and/or (6) PCT patentapplication serial number PCT/US04/10317, filed on Apr. 2, 2004, and/or(7) PCT patent application serial number PCT/US04/10712, filed on Apr.7, 2004, and/or (8) PCT patent application serial number PCT/US04/10762,filed on Apr. 6, 2004, the disclosures of which are incorporated hereinby reference.

In an exemplary embodiment, the extension actuator assembly 26 operatesand is provided substantially, at least in part, as disclosed in one ormore of the following: (1) PCT patent application serial numberPCT/US02/36267, filed on Nov. 12, 2002, and/or (2) PCT patentapplication serial number PCT/US03/29859, filed on Sep. 22, 2003, and/or(3) PCT patent application serial number PCT/US03/13787, filed on May 5,2003, and/or (4) PCT patent application serial number PCT/US03/29460,filed on Sep. 22, 2003, and/or (5) PCT patent application serial numberPCT/US04/07711, filed on Mar. 11, 2004, and/or (6) PCT patentapplication serial number PCT/US04/09434, filed on Mar. 26, 2004, and/or(7) PCT patent application serial number PCT/US04/10317, filed on Apr.2, 2004, and/or (8) PCT patent application serial number PCT/US04/10712,filed on Apr. 7, 2003, and/or (9) PCT patent application serial numberPCT/US04/10762, filed on Apr. 6, 2003, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 15-1, 15-2, 15A1,15A2, 15B1, 15B2, 15C1, 15C2, 15D, 15E1 to 15E5, 15F1 to 15F5, and 15G1to 15G5, the extension actuator assembly 26, combines the functionalityof the casing lock assembly 24 with the functionality of the extensionactuator assembly, and includes a tubular upper tool joint 26002 thatdefines a longitudinal passage 26002 a and mounting holes, 26002 b and26002 c, and includes an internal threaded connection 26002 d at oneend, an external flange 26002 e, an external recess 26002 f having anexternal threaded connection, a tapered recess 26002 g, and an externalrecess 26002 h and an internal recess 26002 i at another end. An end ofan upper pull-nut tube 26004 that defines a longitudinal passage 26004 aand includes an external recess 26004 b and an internally threadedinternal recess 26004 c at another end is received within and mates withthe longitudinal passage 26002 a of the tubular upper tool joint 26002.

An externally threaded end of a tubular inner mandrel 26006 that definesa longitudinal passage 26006 a and radial passages, 26006 b, 26006 c,26006 d, and 26006 e, and includes an externally threaded connection26006 f at another end mates with, is received within, and is coupled tothe internally threaded recess 26004 c of the upper pull-nut tube 26004.An internally threaded end of an lower pull-nut tube 26008 that definesa longitudinal passage 26008 a and includes an external recess 26008 breceives, mates with, and is coupled to externally threaded connection26006 f of the tubular inner mandrel 26006.

An internal flange 26010 a of an end of a tubular lock mandrel 26010that defines a longitudinal passage 26010 b, radial passages, 26010 cand 26010 d, a radial passage 26010 e, and a radial passage 26010 fhaving an internal annular recess 26016 fa and includes an externalflange 26010 g that mates with and is received within the internalrecess 26002 i of the tubular upper tool joint 26002, an externalannular recess 26010 h, an external flange 26010 i, an external flange26010 j, an external flange 26010 k, an external flange 26010 l, anexternal flange 26010 m that includes an external annular recess 26010ma, an external flange 26010 n that defines mounting holes, 26010 o and26010 p, an external annular recess 26010 q, an external annular recess26010 r, and a tapered annular recess 26010 s at another end receivesand mates with the tubular inner mandrel 26006. Internal flanges, 26012a and 26012 b, of a first locking dog 26012 that defines a radialpassage 26012 c and includes spring arms, 26012 d and 26012 e, and anexternal flange 26012 f including external teeth 26012 g are positionedupon the external flanges, 26010 i and 26010 j, of the tubular lockmandrel 26010. Internal flanges, 26014 a and 26014 b, of a secondlocking dog 26014 that defines a radial passage 26014 c and includesspring arms, 26014 d and 26014 e, and an external flange 26014 fincluding external teeth 26014 g are positioned upon the externalflanges, 26010 i and 26010 j, of the tubular lock mandrel 26010.

An internally threaded end of a tubular retainer sleeve 26016 thatdefines a longitudinal passage 26016 a, radial passages, 26016 b and26016 c, at one end, radial passages, 26016 d and 26016 e, for receivingand mating with the external flanges, 26012 f and 26014 f, respectively,of the first and second locking dogs, 26012 and 26014, respectively, andradial passages, 26016 f and 26016 g, at another end and includes atapered internal flange 26016 h, a tapered internal recess 26016 i thatreceives and mates with the spring arms, 26012 d and 26014 d, and endsof the first and second locking dogs, respectively, a tapered internalrecess 26016 j that receives and mates with the springs arms, 26012 eand 26014 e, and other ends of the first and second locking dogs,respectively, a tapered internal flange 26016 k, and an internalthreaded connection 26016 l at another end receives, mates with, and iscoupled to the externally threaded connection 26002 f of the end of thetubular upper tool joint 26002. The ends of the spring arms, 26012 d and26014 d, of the first and second locking dogs, 26012 and 26014,respectively, are held between the internal surface of the end of thetapered internal recess 26016 i of the tubular retainer sleeve 26016 andthe external surface of the end of the tapered external annular recess26002 h of the tubular upper tool joint 26002.

An externally threaded connection 26018 a of an end of a tubularconnector 26018 that defines mounting holes, 26018 a and 26018 b, andmounting holes, 26018 c and 26018 d, and includes a tapered externalannular recess 26018 e at one end, an external annular recess 26018 fand an external annular recess 26018 g at another end is receivedwithin, mates with, and is coupled to the internal threaded connection26016 l of the end of the tubular retainer sleeve 26016. The ends of thespring arms, 26012 e and 26014 e, of the first and second locking dogs,26012 and 26014, respectively, are held between the internal surface ofthe end of the tapered internal recess 26016 j of the tubular retainersleeve 26016 and the external surface of the end of the tapered externalannular recess 26018 e of the tubular connector 26018.

A sealing member 26020 is received within the external annular recess26010 h of the tubular lock mandrel 26010 for sealing the interfacebetween the tubular lock mandrel and the tubular upper tool joint 26002.A sealing member 26022 is received within the external annular recess26010 q of the tubular lock mandrel 26010 for sealing the interfacebetween the tubular lock mandrel and the tubular connector 26018.

A tubular face seal 26024, tubular face seal back-up 26026, a spring26028, and a plunger 26030 are mounted upon and retained upon theexternal annular recess 26018 g of the tubular connector 26018 by a snapring 26032 that is coupled to the external annular recess of the tubularconnector. A burst disk 26034 and tubular burst disk bushing 26036 aremounted within the radial passage 26010 f of the tubular lock mandrel26010, and a sealing member 26038 is received within the internalannular recess 26010 f a of the radial passage of the tubular lockmandrel for sealing the interface between the tubular burst disk bushingand the tubular lock mandrel.

An internally threaded end 26040 a of a tubular release body 26040 thatdefines a longitudinal passage 26040 b, radial passages, 26040 c and26040 d, radial mounting holes, 26040 e and 26040 f, radial mountingholes, 26040 g and 26040 h, and includes an internal flange 26040 i thatmates with and receives the external flange 26010 n of the tubular lockmandrel 26010, an internal flange 26040 j that mates with and receivesthe tubular lock mandrel receives, and an external annular recess 26040k mates with, and is coupled to an externally threaded end 26018 h ofthe tubular connector 26018. A sealing member 26042 received within theexternal annular recess 26018 f of the tubular connector 26018 seals theinterface between the tubular connector and the tubular release body26040. A sealing member 26044 received within the external annularrecess 26010 ma of the tubular lock mandrel 26010 seals the interfacebetween the tubular lock mandrel and the tubular release body 26040.Shear pins, 26046 a and 26046 b, are received within and coupled to theradial mounting holes, 26010 o and 26040 e, and 26010 p and 26040 f,respectively, of the tubular lock mandrel 26010 and tubular release body26040, respectively. Torque pins, 26048 a and 26048 b, are receivedwithin and coupled to the radial mounting holes, 26018 c and 26018 d,respectively, of the tubular connector 26018 that also extend into theradial passages, 26040 c and 26040 d, respectively, of the tubularrelease body 26040. A sealing member 26050 received within the externalannular recess 26010 r of the tubular lock mandrel 26010 seals theinterface between the tubular lock mandrel and the internal flange 26040j of the tubular release body 26040.

An internally threaded end 26052 a of a tubular extender barrel 26052that defines a longitudinal passage 26052 b, radial passages, 26052 cand 26052 d, and radial passages, 26052 e and 26052 f, and includesreceives, mates with, and is coupled to an external threaded connection26040 l of the tubular release body 26040. A sealing member 26054received within the external annular recess 26040 k of the tubularrelease body 26040 seals the interface between the tubular release bodyand the tubular extender barrel 26052.

An external threaded connection 26056 a of an end of a tubular lowerbushing 26056 that defines a longitudinal passage 26056 b and mountingholes, 26056 c and 26056 d, and includes an internal annular recess26056 e, an internal annular recess 26056 f, a plurality ofcircumferentially spaced apart teeth 26056 g at one end, a plurality ofcircumferentially spaced apart teeth 26056 h at another end, and anexternal annular recess 26056 i is received within, mates with, and iscoupled to an internal threaded connection 26052 m of the tubularextender barrel 26052. Torque pins, 26058 a and 26058 b, are mountedwithin and coupled to the mounting holes, 26056 c and 26056 d,respectively, of the tubular lower bushing 26056 that also extend intothe radial passages, 26052 e and 26052 f, respectively, of the tubularextender barrel 26052.

A tubular connecting rod 26060 that defines a longitudinal passage 26060a that receives and mates with the lower pull-nut tube 26008, radialpassages, 26060 b and 26060 c, and radial mounting holes, 26060 d and26060 e, and includes an external threaded connection 26060 f at oneend, and an external threaded connection 26060 g at another end isslidably received within the longitudinal passage 25056 b of the tubularlower bushing 26056. An internal threaded connection 26062 a of an innermandrel tubular piston 26062 that defines mounting holes, 26062 b and26062 c, and includes an internal flange 26062 d at one end thatreceives and mates with the tubular inner mandrel 26006, an externalannular recess 26062 e, and a plurality of circumferentially spacedapart teeth 26062 f at another end receives, mates with, and is coupledto the external threaded connection 26060 f of the tubular connectingrod 26060.

Torque screws, 26064 a and 26064 b, are mounted within and coupled tothe mounting holes, 26062 b and 26062 c, respectively, of the innermandrel tubular piston 26062 that also extend into the radial passages,26060 b and 26060 c, of the tubular connecting rod 26060. A sealingmember 26066 positioned within the external annular recess 26062 e ofthe inner mandrel tubular piston 26062 seals the interface between theinner tubular piston and the tubular extender barrel 26052. A sealingmember 26068 positioned within the external annular recess 26056 i ofthe tubular lower bushing 26056 seals the interface between the tubularlower bushing and the tubular extender barrel 26052.

A packing sealing element 26070 is received within the internal annularrecess 25056 f of the tubular lower bushing 26056, and a packingretainer 26072 is received within the internal annular recess 26056 e ofthe tubular lower bushing for sealing the interface between the tubularlower bushing and the tubular connecting rod 26060. The packing sealingelement 26070 and the packing retainer 26072 are retained within theinternal annular recess 25056 f of the tubular lower bushing 26056 andinternal annular recess 26056 e of the tubular lower bushing,respectively, by a snap ring 26074 that is coupled to the tubularconnecting rod 26060.

An internally threaded connection 26076 a of a tubular lower tool joint26076 that defines a longitudinal passage 26076 b, radial mountingholes, 26076 c and 26076 d, and radial mounting holes, 26076 e and 26076f, and includes an internal annular recess 26076 g and an externalannular recess 26076 h receives, mates with, and is coupled to anexternal threaded connection 26060 g of the tubular connecting rod26060. Torque screws, 26078 a and 26078 b, are mounted within andcoupled to the mounting holes, 26076 c and 26076 d, respectively, of thetubular lower tool joint 26076 that also extend into the radialpassages, 26060 d and 26060 e, of the tubular connecting rod 26060. Asealing member 26080 is received within the internal annular recess26076 g of the tubular lower tool joint 26076 for sealing the interfacebetween the tubular lower tool joint and the tubular connecting rod26060.

In an exemplary embodiment, during operation of the extension actuatorassembly 26, as illustrated in FIGS. 15E1 to 15E5, the extensionactuator assembly is positioned within the wellbore 102, the internalthreaded connection 26002 d of the tubular upper tool joint 26002receives, mates with, and is coupled to an end of the sealing cupassembly 22, and the end of the tubular lower tool joint 26076 isreceived within, mates with, and is coupled to an end of the adjustablebell section expansion cone assembly 28. In an exemplary embodiment, aportion 100 a of the expandable wellbore casing 100 includes internalteeth 100 b that engage with, and are coupled to, the external teeth,26012 g and 26014 g, of the first and second locking dogs, 26012 and26014, respectively. In this manner, the expandable wellbore casing 100is locked to the extension actuator assembly 26 of the system 10.

In an exemplary embodiment, during the operation of the extensionactuator assembly 26, a fluidic material 26100 may then be injected intothe extension actuator assembly through the longitudinal passages 26004a, 26006 a, and 26008 a of the upper pull-nut tube 26004, tubular innermandrel 26006, and lower pull-nut tube 26008, respectively, therebypressurizing the longitudinal passages of the upper pull-nut tube,tubular inner mandrel, and lower pull-nut tube. As a result, the fluidicmaterial 26100 is also conveyed through the radial passage 26006 c ofthe tubular inner mandrel 26006 into and through an annulus 26102defined between the tubular inner mandrel and the tubular lock mandrel26010. The fluidic material 26100 is then conveyed into an annulus 26104defined between the tubular inner mandrel 26006 and the tubular extenderbarrel 26052 proximate an end face of the inner mandrel tubular piston26062.

In an exemplary embodiment, as illustrated in FIGS. 15F1 to 15F5, thecontinued injection of the fluidic material 26100 into the extensionactuator assembly 26 will then displace the inner mandrel tubular piston26062 downwardly in a direction 26106. As a result, the tubularconnecting rod 26060 and the tubular lower tool joint 26076 are alsodisplaced downwardly in the direction 26106.

In an exemplary embodiment, as illustrated in FIGS. 15G1 to 15G5, thecontinued injection of the fluidic material 26100 into the extensionactuator assembly 26 will then further displace the inner mandreltubular piston 26062 downwardly in the direction 26106 until an end faceof the inner flange 26062 d of the inner mandrel tubular piston engagesan end face of the lower pull-nut tube 26008. As a result, the lowerpull-nut tube 26008, the tubular inner mandrel 26006, the upper pull-nuttube 26004, and the tubular lock mandrel 26010 are also displaceddownwardly in the direction 26106 thereby shearing the shear pins, 26064a and 26064 b, and disengaging the tubular lock mandrel from the tubularrelease body 26040.

The continued injection of the fluidic material 26100 into the extensionactuator assembly 26 will then further displace the tubular lock mandrel26010 downwardly in the direction 26106 thereby displacing the externalflanges, 26010 i and 26010 j, of the tubular lock mandrel out ofengagement with the internal flanges, 26012 a and 26012 b, and 26014 aand 26014 b, of the first and second locking dogs, 26012 and 26014,respectively. As a result, a spring bias force in an inner radialdirection is applied by the spring arms, 26012 d and 26012 e, and 26014d and 26014 e, of the first and second locking dogs, 26012 and 26014,respectively, to the first and second locking dogs thereby displacingthe first and second locking dogs in an inner radial direction out ofengagement with the portion 100 a of the expandable wellbore casing 100.As a result, the expandable wellbore casing 100 is no longer locked tothe first and second locking dogs, 26012 and 26014, of the extensionactuator assembly 26.

In an exemplary embodiment, during operation of the extension actuatorassembly 26, the expandable wellbore casing 100 may also be un-lockedfrom engagement with the first and second locking dogs, 26012 and 26014,of the extension actuator assembly by increasing the operating pressureof the fluidic material 26100 above a predetermined level sufficient torupture the burst disk 26034. As a result, the fluidic material 26100will enter an annulus 26108 defined between the tubular lock mandrel26010 and the tubular release body 26040. As a result, the tubular lockmandrel 26010 will be displaced downwardly in the direction 26106thereby displacing the external flanges, 26010 i and 26010 j, of thetubular lock mandrel out of engagement with the internal flanges, 26012a and 26012 b, and 26014 a and 26014 b, of the first and second lockingdogs, 26012 and 26014, respectively. As a result, a spring bias force inan inner radial direction is applied by the spring arms, 26012 d and26012 e, and 26014 d and 26014 e, of the first and second locking dogs,26012 and 26014, respectively, to the first and second locking dogsthereby displacing the first and second locking dogs in an inner radialdirection out of engagement with the portion 100 a of the expandablewellbore casing 100. As a result, the expandable wellbore casing 100 isno longer locked to the first and second locking dogs, 26012 and 26014,of the extension actuator assembly 26. In an exemplary embodiment, thepredetermined operating pressure of the fluidic material 26100sufficient to rupture the burst disk 26034 is selected to provide arelease of the expandable wellbore casing 100 from engagement with thefirst and second locking dogs, 26012 and 26104, in the event of anemergency operating condition during the operation of the system 10.

In an exemplary embodiment, the pressurization of the longitudinalpassages 26004 a, 26006 a, and 26008 a of the upper pull-nut tube 26004,tubular inner mandrel 26006, and lower pull-nut tube 26008,respectively, caused by the injection of the fluidic material 26100 maybe further enhanced by blocking the flow of the fluidic material tothose portions of the system 10 downstream from the extension actuatorassembly 26 by, for example, blocking flow through a flow restrictiondefined in one or more of the elements of the system downstream of theextension actuator assembly by placing a ball or plug in one or more ofthose flow restrictions.

In an exemplary embodiment, the adjustable bell section expansion coneassembly 28 operates and is provided substantially, at least in part, asdisclosed in one or more of the following: (1) PCT patent applicationserial number PCT/US02/36157, filed on Nov. 12, 2002, and/or (2) PCTpatent application serial number PCT/US02/36267, filed on Nov. 12, 2002,and/or (3) PCT patent application serial number PCT/US03/04837, filed onFeb. 29, 2003, and/or (4) PCT patent application serial numberPCT/US03/29859, filed on Sep. 22, 2003, and/or (5) PCT patentapplication serial number PCT/US03/14153, filed on Nov. 13, 2003, and/or(6) PCT patent application serial number PCT/US03/18530, filed on Jun.11, 2003, and/or (7) PCT patent application serial numberPCT/US04/07711, filed on Mar. 11, 2004, and/or (8) PCT patentapplication serial number PCT/US04/09434, filed on Mar. 26, 2004, and/or(9) PCT patent application serial number PCT/US04/10317, filed on Apr.2, 2004, and/or (10) PCT patent application serial numberPCT/US04/10712, filed on Apr. 7, 2004, and/or (11) PCT patentapplication serial number PCT/US04/10762, filed on Apr. 6, 2004, thedisclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 16-1 and 16-2, 16A1to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F, 16G, 16H, 16I, 16 j, 16K,16L, 16M, 16N, 160, 16P, 16R, 16S, 16T, 16U, 16V, 16W, 16 x, 16Y, 16Z1to 16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE,the adjustable bell section expansion cone assembly 28 includes an uppertubular tool joint 28002 that defines a longitudinal passage 28002 a andmounting holes, 28002 b and 28002 c, and includes an internal threadedconnection 28002 d, an inner annular recess 28002 e, an inner annularrecess 28002 f, and an internal threaded connection 28002 g. A tubulartorque plate 28004 that defines a longitudinal passage 28004 a andincludes circumferentially spaced apart teeth 28004 b is receivedwithin, mates with, and is coupled to the internal annular recess 28002e of the upper tubular tool joint 28002.

Circumferentially spaced apart teeth 28006 a of an end of a tubularlower mandrel 28006 that defines a longitudinal passage 28006 b, aradial passage 28006 ba, and a radial passage 28006 bb and includes anexternal threaded connection 28006 c, an external flange 28006 d, anexternal annular recess 28006 e having a step 28006 f at one end, anexternal annular recess 28006 g, external teeth 28006 h, an externalthreaded connection 28006 i, and an external annular recess 28006 jengage the circumferentially spaced apart teeth 28004 b of the tubulartorque plate 28004. An internal threaded connection 28008 a of an end ofa tubular toggle bushing 28008 that defines a longitudinal passage 28008b, an upper longitudinal slot 28008 c, a lower longitudinal slot 28008d, mounting holes, 28008 e, 28008 f, 28008 g, 28008 h, 28008 i, 28008 j,28008 k, 28008 l, 28008 m, 28008 n, 28008 o, 28008 p, 28008 q, 28008 r,28008 s, 28008 t, 28008 u, 28008 v, 28008 w, 28008 x, 28008 xa, and28008 xb, and includes an external annular recess 28008 y, internalannular recess 28008 z, external annular recess 28008 aa, and anexternal annular recess 28008 ab receives and is coupled to the externalthreaded connection 28006 c of the tubular lower mandrel 28006.

A sealing element 28010 is received within the external annular recess28008 y of the tubular toggle bushing 28008 for sealing the interfacebetween the tubular toggle bushing and the upper tubular tool joint28002. A sealing element 28012 is received within the internal annularrecess 28008 z of the tubular toggle bushing 28008 for sealing theinterface between the tubular toggle bushing and the tubular lowermandrel 28006.

Mounting screws, 28014 a and 28014 b, mounted within and coupled to themounting holes, 28008 w and 28008 x, respectively, of the tubular togglebushing 28008 are also received within the mounting holes, 28002 b and28002 c, of the upper tubular tool joint 28002. Mounting pins, 28016 a,28016 b, 28016 c, 28016 d, and 28016 e, are mounted within the mountingholes, 28008 e, 28008 f, 28008 g, 28008 h, and 28008 i, respectively.Mounting pins, 28018 a, 28018 b, 28018 c, 28018 d, and 28018 e, aremounted within the mounting holes, 28008 t, 28008 s, 28008 r, 28008 q,and 28008 p, respectively. Mounting screws, 28020 a and 28020 b, aremounted within the mounting holes, 28008 u and 28008 v, respectively.

A first upper toggle link 28022 defines mounting holes, 28022 a and28022 b, for receiving the mounting pins, 28016 a and 28016 b, andincludes a mounting pin 28022 c at one end. A first lower toggle link28024 defines mounting holes, 28024 a, 28024 b, and 28024 c, forreceiving the mounting pins, 28022 c, 28016 c, and 28016 d, respectivelyand includes an engagement arm 28024 d. A first trigger 28026 defines amounting hole 28026 a for receiving the mounting pin 28016 e andincludes an engagement arm 28026 b at one end, an engagement member28026 c, and an engagement arm 28026 d at another end.

A second upper toggle link 28028 defines mounting holes, 28028 a and28028 b, for receiving the mounting pins, 28018 a and 28018 b, andincludes a mounting pin 28028 c at one end. A second lower toggle link28030 defines mounting holes, 28030 a, 28030 b, and 28030 c, forreceiving the mounting pins, 28028 c, 28018 c, and 28018 d, respectivelyand includes an engagement arm 28030 d. A second trigger 28032 defines amounting hole 28032 a for receiving the mounting pin 28018 e andincludes an engagement arm 28032 b at one end, an engagement member28032 c, and an engagement arm 28032 d at another end.

An end of a tubular spring housing 28034 that defines a longitudinalpassage 28034 a, mounting holes, 28034 b and 28034 c, and mountingholes, 28034 ba and 28034 ca, and includes an internal flange 28034 dand an internal annular recess 28034 e at one end, and an internalflange 28034 f, an internal annular recess 28034 g, an internal annularrecess 28034 h, and an external threaded connection 28034 i at anotherend receives and mates with the end of the tubular toggle bushing 28008.Mounting screws, 28035 a and 28035 b, are mounted within and coupled tothe mounting holes, 28008 xb and 28008 xa, respectively, of the tubulartoggle bushing 28008 and are received within the mounting holes, 28034ba and 28034 ca, respectively, of the tubular spring housing 28034.

A tubular retracting spring ring 28036 that defines mounting holes,28036 a and 28036 b, receives and mates with a portion of the tubularlower mandrel 28006 and is received within and mates with a portion ofthe tubular spring housing 28034. Mounting screws, 28038 a and 28038 b,are mounted within and coupled to the mounting holes, 28036 a and 28036b, respectively, of the tubular retracting spring ring 28036 and extendinto the mounting holes, 28034 b and 28034 c, respectively, of thetubular spring housing 28034.

Casing diameter sensor springs, 28040 a and 28040 b, are positionedwithin the longitudinal slots, 28008 c and 2808 d, respectively, of thetubular toggle bushing 28008 that engage the engagement members, 28026 cand 28032 c, and engagement arms, 28026 d and 28032 d, of the first andsecond triggers, 28026 and 28032, respectively. An inner flange 28042 aof an end of a tubular spring washer 28042 mates with and receives aportion of the tubular lower mandrel 28006 and an end face of the innerflange of the tubular spring washer is positioned proximate and end faceof the external flange 28006 d of the tubular lower mandrel. The tubularspring washer 28042 is further received within the longitudinal passage28034 a of the tubular spring housing 28034.

An end of a retracting spring 28044 that receives the tubular lowermandrel 28006 is positioned within the tubular spring washer 28042 incontact with the internal flange 28042 a of the tubular spring washerand the other end of the retracting spring is positioned in contact withan end face of the tubular retracting spring ring 28036.

A sealing element 28046 is received within the external annular recess28006 j of the tubular lower mandrel 28006 for sealing the interfacebetween the tubular lower mandrel and the tubular spring housing 28034.A sealing element 28048 is received within the internal annular recess28034 h of the tubular spring housing 28034 for sealing the interfacebetween the tubular spring housing and the tubular lower mandrel 28006.

An internal threaded connection 28050 a of an end of a tubular upperhinge sleeve 28050 that includes an internal flange 28050 b and aninternal pivot 28050 c receives and is coupled to the external threadedconnection 28034 l of the end of the tubular spring housing 28034.

An external flange 28052 a of a base member 28052 b of an upper camassembly 28052, that is mounted upon and receives the lower tubularmandrel 28006, that includes an internal flange 28052 c that is receivedwithin the external annular recess 28006 e of the lower tubular mandrel28006 and a plurality of circumferentially spaced apart tapered cam arms28052 d extending from the base member mates with and is received withinthe tubular upper hinge sleeve 28050. The base member 28052 b of theupper cam assembly 28052 further includes a plurality ofcircumferentially spaced apart teeth 28052 f that mate with and arereceived within a plurality of circumferentially spaced apart teeth28034 j provided on the end face of the tubular spring housing 28034 andan end face of the external flange 28052 a of the base member of theupper cam assembly is positioned in opposing relation to an end face ofthe internal flange 28050 b of the tubular upper hinge sleeve 28050.Each of the cam arms 28052 d of the upper cam assembly 28052 includeexternal cam surfaces 28052 e. In an exemplary embodiment, the teeth28052 f of the base member 28052 b of the upper cam assembly 28052 andthe teeth 28034 j provided on the end face of the tubular spring housing28034 permit torsional loads to be transmitted between the tubularspring housing and the upper cam assembly.

A plurality of circumferentially spaced apart upper expansion segments28054 are mounted upon and receive the lower tubular mandrel 28006 andeach include an external pivot recess 28054 a at one end for mating withand receiving the internal pivot 28050 c of the tubular upper hingesleeve 28050 and an external tapered expansion surface 28054 b atanother end and are pivotally mounted within the tubular upper hingesleeve and are interleaved with the circumferentially spaced apart camarms 28052 d of the upper cam assembly 28052. The upper expansionsegments 28054 are interleaved among the cam arms 28052 d of the uppercam assembly 28052.

A plurality of circumferentially spaced apart lower expansion segments28058 are mounted upon and receive the lower tubular mandrel 28006, areinterleaved among the upper expansion segments 28054, are oriented inthe opposite direction to the upper expansion segments 28054, eachinclude an external pivot recess 28058 a at one end and an externaltapered expansion surface 28054 b at another end and are positioned inopposing relation to corresponding circumferentially spaced apart camarms 28052 d of the upper cam assembly 28052.

A lower cam assembly 28060 is mounted upon and receives the lowertubular mandrel 28006 that includes a base member 28060 a having anexternal flange 28060 b, a plurality of circumferentially spaced apartcam arms 28060 d that extend from the base member that each includeexternal cam surfaces 28060 e and define mounting holes 28060 f and28060 g. The base member 28060 a of the lower cam assembly 28060 furtherincludes a plurality of circumferentially spaced apart teeth 28060 h.The circumferentially spaced apart cam arms 28060 d of the lower camassembly 28060 are interleaved among the lower expansion segments 28058and the circumferentially spaced apart cam arms 28052 d of the upper camassembly 28052 and positioned in opposing relation to correspondingupper expansion segments 28054.

Mounting screws, 28062 a, 28062 b, 28062 c, and 28062 e, are mountedwithin the corresponding mounting holes, 28060 f and 28060 g, of thelower cam assembly 28060 and are received within the external annularrecess 28006 g of the lower cam assembly 28060.

A tubular lower hinge sleeve 28064 that receives the lower expansionsegments 28058 and the lower cam assembly 28060 includes an internalflange 28064 a for engaging the external flange 28060 b of the basemember of the lower cam assembly 28060, an internal pivot 28064 b forengaging and receiving the external pivot recess 28058 a of the lowerexpansion segments 28058 thereby pivotally mounting the lower expansionsegments within the tubular lower hinge sleeve, and an internal threadedconnection 28064 c.

An external threaded connection 28066 a of an end of a tubular sleeve28066 that defines mounting holes, 28066 b and 28066 c, and includes aninternal annular recess 28066 d having a shoulder 28066 e, an internalflange 28066 f, and an internal threaded connection 28066 g at anotherend is received within and coupled to the internal threaded connection28064 c of the tubular lower hinge sleeve 28064. An external threadedconnection 28068 a of an end of a tubular member 28068 that defines alongitudinal passage 28068 b and mounting holes, 28068 c and 28068 d,and includes an external annular recess 28068 e, and an externalthreaded connection 28068 f at another end is received within and iscoupled to the internal threaded connection 28066 g of the tubularsleeve 28066.

Mounting screws, 28070 a and 28070 b, are mounted in and coupled to themounting holes, 28068 c and 28068 d, respectively, of the tubular member28068 that also extend into the mounting holes, 28066 b and 28066 c,respectively, of the tubular sleeve 28066. A sealing element 28072 isreceived within the external annular recess 28068 e of the tubularmember 28068 for sealing the interface between the tubular member andthe tubular sleeve 28066.

An internal threaded connection 28074 a of a tubular retracting piston28074 that defines a longitudinal passage 28074 b and includes aninternal annular recess 28074 c and an external annular recess 28074 dreceives and is coupled to the external threaded connection 28006 i ofthe tubular lower mandrel 28006. A sealing element 28076 is receivedwithin the external annular recess 28074 d of the tubular retractingpiston 28074 for sealing the interface between the tubular retractingpiston and the tubular sleeve 28066. A sealing element 28078 is receivedwithin the internal annular recess 28074 c of the tubular retractingpiston 28074 for sealing the interface between the tubular retractingpiston and the tubular lower mandrel 28006.

Locking dogs 28080 mate with and receive the external teeth 28006 h ofthe tubular lower mandrel 28006. A spacer ring 28082 is positionedbetween an end face of the locking dogs 28080 and an end face of thelower cam assembly 28060. A release piston 28084 mounted upon thetubular lower mandrel 28006 defines a radial passage 28084 a formounting a burst disk 28086 includes sealing elements, 28084 b, 28084 c,and 28084 d. The sealing elements, 28084 b and 28084 d, sealing theinterface between the release piston 28084 and the tubular lower mandrel28006. An end face of the release piston 28084 is positioned in opposingrelation to an end face of the locking dogs 28080.

A release sleeve 28088 that receives and is mounted upon the lockingdogs 28080 and the release piston 28084 includes an internal flange28088 a at one end that sealingly engages the tubular lower mandrel28006. A bypass sleeve 28090 that receives and is mounted upon therelease sleeve 28088 includes an internal flange 28090 a at one end.

In an exemplary embodiment, during operation of the adjustable bellsection expansion cone assembly 28, the retracting spring 28044 iscompressed and thereby applies a biasing spring force in a direction28092 from the lower tubular mandrel 28006 to the tubular spring housing28634 that, in the absence of other forces, moves and/or maintains theupper cam assembly 28052 and the upper expansion segments 28054 out ofengagement with the lower expansion segments 28058 and the lower camassembly 28060. In an exemplary embodiment, during operation of theadjustable bell section expansion cone assembly 28, an external threadedconnection 26 a of an end of the extension actuator assembly 26 iscoupled to the internal threaded connection 28002 d of the upper tubulartool joint 28002 and an internal threaded connection 30 a of an end ofthe adjustable casing expansion cone assembly 30 is coupled to theexternal threaded connection 28068 f of the tubular member 28068.

The upper cam assembly 28052 and the upper expansion segments 28054 maybe brought into engagement with the lower expansion segments 28058 andthe lower cam assembly 28060 by pressurizing an annulus 28094 definedbetween the lower tubular mandrel 28006 and the tubular spring housing28034. In particular, injection of fluidic materials into the adjustablebell section expansion cone assembly 28 through the longitudinal passage28006 b of the lower tubular mandrel 28006 and into the radial passage28006 ba may pressurize the annulus 28094 thereby creating sufficientoperating pressure to generate a force in a direction 28096 sufficientto overcome the biasing force of the retracting spring 28044. As aresult, the spring housing 28034 may be displaced in the direction 28096relative to the lower tubular mandrel 28006 thereby displacing thetubular upper hinge sleeve 28050, upper cam assembly 28052, and upperexpansion segments 28054 in the direction 28096.

In an exemplary embodiment, as illustrated in FIGS. 16P and 16R, thedisplacement of the upper cam assembly 28052 and upper expansionsegments 28054 in the direction 28096 will cause the lower expansionsegments 28058 to ride up the cam surfaces 28052 e of the cam arms 28052d of the upper cam assembly 28052 while also pivoting about the lowertubular hinge segment 28064, and will also cause the upper expansionsegments 28054 to ride up the cam surfaces 28060 e of the cam arms 28060d of the lower cam assembly 28060 while also pivoting about the uppertubular hinge segment 28050. In an exemplary embodiment, when the upperand lower expansion segments, 28054 and 28058, are brought into axialalignment, they define an outer expansion surface that is approximatelycontiguous in a circumferential direction and which provides an outerexpansion surface that at least approximates a conical surface.

In an exemplary embodiment, during the operation of the adjustable bellsection expansion cone assembly 28, when the upper and lower expansionsegments, 28054 and 28058, brought into axial alignment into a radiallyexpanded position, the upper and lower expansion segments, 28054 and28058, are displaced relative to the expandable wellbore casing 100 tothereby radially expand and plastically deform at least a portion of theexpandable wellbore casing. In an exemplary embodiment, during theradial expansion and plastic deformation of the expandable wellborecasing 100, the adjustable bell section expansion cone assembly 28 maythen be rotated relative to the expandable wellbore casing to enhanceand/or modify the rate at which the expandable wellbore casing isradially expanded and plastically deformed.

In an exemplary embodiment, the upper cam assembly 28052 and the upperexpansion segments 28054 may be moved out of engagement with the lowerexpansion segments 28058 and the lower cam assembly 28060 by reducingthe operating pressure within the annulus 28094.

In an alternative embodiment, as illustrated in FIGS. 16S, 16T, 16U and16V, during operation of the adjustable bell section expansion coneassembly 28, the upper cam assembly 28052 and the upper expansionsegments 28054 may also be moved out of engagement with the lowerexpansion segments 28058 and the lower cam assembly 28060 by sensing theoperating pressure within the longitudinal passage 28006 b of the lowertubular mandrel 28006. In particular, as illustrated in FIG. 16T, if theoperating pressure within the longitudinal passage 28006 b and radialpassage 28006 bb of the lower tubular mandrel 28006 exceeds apredetermined value, the burst disc 28086 will open the passage 28084 athereby pressurizing the interior of the tubular release sleeve 28088thereby displacing the tubular release sleeve 28088 downwardly in adirection 28092 away from engagement with the locking dogs 28080.

As a result, as illustrated in FIG. 16U, the locking dogs 28080 aredisplaced outwardly in the radial directed and thereby released fromengagement with the lower tubular mandrel 28006 thereby permitting thelower expansion segments 28058 and the lower cam assembly 28060 to bedisplaced downwardly relative to the lower tubular mandrel.

As a result, as illustrated in FIG. 16V, the operating pressure withinthe lower tubular mandrel 28066 may then cause the lower tubular mandrelto be displaced downwardly in the direction 28094 relative to thetubular lower mandrel 28006 and the retracting piston 28074. As aresult, the lower tubular mandrel 28066, the lower expansion segments28058, the lower cam assembly 28060, and tubular lower hinge sleeve28064 are displaced downwardly in the direction 28094 relative to thetubular spring housing 28034 thereby moving the lower expansion segments28058 and the lower cam assembly 28060 out of engagement with the uppercam assembly 28052 and the upper expansion segments 28054.

In an exemplary embodiment, as illustrated in FIGS. 16W, 16X, and 16Y,during operation of the adjustable bell section expansion cone assembly28, the adjustable bell section expansion cone assembly senses thediameter of the expandable wellbore casing 100 using the upper togglelinks, 28022 and 28028, lower toggle links, 28024 and 28030, andtriggers, 28026 and 28032, and then prevents the engagement of the uppercam assembly 28052 and the upper expansion segments 28054 with the lowerexpansion segments 28058 and the lower cam assembly 28060.

In particular, as illustrated in FIG. 16W, anytime the upper togglelinks, 28022 and 28028, and lower toggle links, 28024 and 28030, arepositioned within a portion of the expandable wellbore casing 100 thathas been radially expanded and plastically deformed by the system 10,the triggers, 28026 and 28032, will be pivoted by the engagement arms,28024 d and 28030 d, of the lower toggle links, 28024 and 28030, to aposition in which the triggers will no longer engage the internal flange28034 d of the end of the tubular spring housing 28034 therebypermitting the displacement of the tubular spring housing in thedirection 28096. As a result, the upper cam assembly 28052 and the upperexpansion segments 28054 can be brought into engagement with the lowerexpansion segments 28058 and the lower cam assembly 28060. In anexemplary embodiment, the upper toggle links, 28022 and 28028, and thelower toggle links, 28024 and 28030, are spring biased towards theposition illustrated in FIG. 16W.

Conversely, as illustrated in FIG. 16X, anytime the upper toggle links,28022 and 28028, and lower toggle links, 28024 and 28030, are positionedwithin a portion of the expandable wellbore casing 100 that has not beenradially expanded and plastically deformed by the system 10, thetriggers, 28026 and 28032, will be maintained in a position in which thetriggers will engage the internal flange 28034 d of the end of thetubular spring housing 28034 thereby preventing the displacement of thetubular spring housing in the direction 28096. As a result, the uppercam assembly 28052 and the upper expansion segments 28054 cannot bebrought into engagement with the lower expansion segments 28058 and thelower cam assembly 28060. In an exemplary embodiment, the triggers,28026 and 28032, are spring biased towards the position illustrated inFIG. 16X.

In an exemplary embodiment, as illustrated in FIG. 16Y, the tubularspring housing 28034 may be displaced upwardly in the direction 28098even if the upper toggle links, 28022 and 28028, and lower toggle links,28024 and 28030, are positioned within a portion of the expandablewellbore casing 100 that has not been radially expanded and plasticallydeformed by the system 10.

In an exemplary embodiment, as illustrated in FIGS. 16Z1 to 16Z4, 16AA1to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE, the tubularspring housing 28034 of the adjustable bell section expansion coneassembly 28 defines internal annular recesses 28034 k and 28034 l,spaced apart by an internal flange 28034 m, the tubular toggle bushing28008 defines an external annular recess 28008 ac, and the adjustablebell section expansion cone assembly further includes pins, 28100 a and28100 b and 28102 a and 28102 b, mounted in holes 28008 j and 28008 oand 28008 k and 28008 n, respectively, of the tubular toggle bushing,and a one-shot deactivation device 28104 mounted on the tubular togglebushing between the pins, 28100 a and 28100 b and 28102 a and 28102 b.

The one-shot deactivation device 28104 includes a tubular body 28104 athat defines radial holes, 28104 b and 28014 c, and includes an externalannular recess 28104 d at one end, a centrally positioned externalflange 28104 e, a centrally positioned internal annular recess 28104 f,and an external annular recess 28104 g at another end. An engagementmember 28106 that includes a base member 28106 a having a tapered end28106 b and a key member 28106 c having a tapered end 28106 d isreceived within a portion of the internal annular recess 28104 f of thetubular body 28104 a and an engagement member 28108 that includes a basemember 28108 a having a tapered end 28108 b and a key member 28108 chaving a tapered end 28108 d is received within an opposite portion ofthe internal annular recess 28104 f of the tubular body 28104 a. Springmembers, 28110 and 28112, are received within the annular recess 28104 fof the tubular body 28104 a for biasing the base members, base member28106 a and 28108 a, of the engagement members, 28106 and 28108,respectively, radially inwardly relative to the tubular body 28104 a.

In an exemplary embodiment, during operation of the adjustable bellsection expansion cone assembly 28, as illustrated in FIGS. 16Z1 to16Z4, the one-shot deactivation device 28104 are positioned proximateand in intimate contact with the pins, 28102 a and 28102 b, with thetapered ends, 28106 b and 28108 b, of the base members, 28106 a and28108 a, of the engagement members, 28106 and 28108, received within theexternal annular recess 28008 ac of the tubular toggle bushing 28008.When the one-shot deactivation device 28104 is positioned as illustratedin FIGS. 16Z1 to 16Z4, the external annular recess 28104 d of thetubular body 28104 a of the one-shot deactivation device is moved out ofengagement with the engagement arms, 28026 d and 28032 d, of thetriggers, 28026 and 28032, respectively. As a result, the triggers,28026 and 28032, may operate normally as described above with referenceto FIGS. 16W, 16X, and 16Y.

Conversely, in an exemplary embodiment, during operation of theadjustable bell section expansion cone assembly 28, as illustrated inFIGS. 16AA1 to 16AA4, the one-shot deactivation device 28104 arepositioned proximate and in intimate contact with the pins, 28100 a and28100 b, with the tapered ends, 28106 b and 28108 b, of the basemembers, 28106 a and 28108 a, of the engagement members, 28106 and28108, not received within the external annular recess 28008 ac of thetubular toggle bushing 28008. When the one-shot deactivation device28104 is positioned as illustrated in FIG. 16AA, the external annularrecess 28104 d of the tubular body 28104 a of the one-shot deactivationdevice is moved into engagement with the engagement arms, 28026 d and28032 d, of the triggers, 28026 and 28032, respectively. As a result,the triggers, 28026 and 28032, are deactivated and may not operatenormally as described above with reference to FIGS. 16W, 16X, and 16Y.

In an alternative embodiment, the elements of the adjustable bellsection expansion cone assembly 28 that sense the diameter of theexpandable wellbore casing 100 may be disabled or omitted or adjusted tosense any pre-selected internal diameter of the expandable wellborecasing.

In an exemplary embodiment, the adjustable casing expansion coneassembly 30 operates and is provided substantially, at least in part, asdisclosed in one or more of the following: (1) PCT patent applicationserial number PCT/US02/36157, filed on Nov. 12, 2002, and/or (2) PCTpatent application serial number PCT/US02/36267, filed on Nov. 12, 2002,and/or (3) PCT patent application serial number PCT/US03/04837, filed onFeb. 29, 2003, and/or (4) PCT patent application serial numberPCT/US03/29859, filed on Sep. 22, 2003, and/or (5) PCT patentapplication serial number PCT/US03/14153, filed on Nov. 13, 2003, and/or(6) PCT patent application serial number PCT/US03/18530, filed on Jun.11, 2003, and/or (7) PCT patent application serial numberPCT/US04/07711, filed on Mar. 11, 2004, and/or (8) PCT patentapplication serial number PCT/US04/09434, filed on Mar. 26, 2004, and/or(9) PCT patent application serial number PCT/US04/10317, filed on Apr.2, 2004, and/or (10) PCT patent application serial numberPCT/US04/10712, filed on Apr. 7, 2004, and/or (10) PCT patentapplication serial number PCT/US04/10762, filed on Apr. 6, 2004, thedisclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 17-1 and 17-2, 17A1to 17A2, 17B1 to 17B2, 17C, 17D, 17E, 17F, 17G, 17H, 17I, 17 j, 17K,17L, 17M, 17N, 170, 17P, 17R, 17S, 17T, 17U, 17V, 17W, 17 x, 17Y,17Z1-17Z4, 17AA1 to 17AA4, 17AB1 to 17AB4, 17AC1 to 17AC4, 17AD, and17AE, the adjustable casing expansion cone assembly 30 includes an uppertubular tool joint 30002 that defines a longitudinal passage 30002 a andmounting holes, 30002 b and 30002 c, and includes an internal threadedconnection 30002 d, an inner annular recess 30002 e, an inner annularrecess 30002 f, and an internal threaded connection 30002 g. A tubulartorque plate 30004 that defines a longitudinal passage 30004 a andincludes circumferentially spaced apart teeth 30004 b is receivedwithin, mates with, and is coupled to the internal annular recess 30002e of the upper tubular tool joint 30002.

Circumferentially spaced apart teeth 30006 a of an end of a tubularlower mandrel 30006 that defines a longitudinal passage 30006 b, aradial passage 30006 ba, and a radial passage 30006 bb and includes anexternal threaded connection 30006 c, an external flange 30006 d, anexternal annular recess 30006 e having a step 30006 f at one end, anexternal annular recess 30006 g, external teeth 30006 h, an externalthreaded connection 30006 i, and an external annular recess 30006 jengage the circumferentially spaced apart teeth 30004 b of the tubulartorque plate 30004. An internal threaded connection 30008 a of an end ofa tubular toggle bushing 30008 that defines a longitudinal passage 30008b, an upper longitudinal slot 30008 c, a lower longitudinal slot 30008d, mounting holes, 30008 e, 30008 f, 30008 g, 30008 h, 30008 i, 30008 j,30008 k, 30008 l, 30008 m, 30008 n, 30008 o, 30008 p, 30008 q, 30008 r,30008 s, 30008 t, 30008 u, 30008 v, 30008 w, 30008 x, 30008 xa, and30008 xb, and includes an external annular recess 30008 y, internalannular recess 30008 z, external annular recess 30008 aa, and anexternal annular recess 30008 ab receives and is coupled to the externalthreaded connection 30006 c of the tubular lower mandrel 30006.

A sealing element 30010 is received within the external annular recess30008 y of the tubular toggle bushing 30008 for sealing the interfacebetween the tubular toggle bushing and the upper tubular tool joint30002. A sealing element 30012 is received within the internal annularrecess 30008 z of the tubular toggle bushing 30008 for sealing theinterface between the tubular toggle bushing and the tubular lowermandrel 30006.

Mounting screws, 30014 a and 30014 b, mounted within and coupled to themounting holes, 30008 w and 30008 x, respectively, of the tubular togglebushing 30008 are also received within the mounting holes, 30002 b and30002 c, of the upper tubular tool joint 30002. Mounting pins, 30016 a,30016 b, 30016 c, 30016 d, and 30016 e, are mounted within the mountingholes, 30008 e, 30008 f, 30008 g, 30008 h, and 30008 i, respectively.Mounting pins, 30018 a, 30018 b, 30018 c, 30018 d, and 30018 e, aremounted within the mounting holes, 30008 t, 30008 s, 30008 r, 30008 q,and 30008 p, respectively. Mounting screws, 30020 a and 30020 b, aremounted within the mounting holes, 30008 u and 30008 v, respectively.

A first upper toggle link 30022 defines mounting holes, 30022 a and30022 b, for receiving the mounting pins, 30016 a and 30016 b, andincludes a mounting pin 30022 c at one end. A first lower toggle link30024 defines mounting holes, 30024 a, 30024 b, and 30024 c, forreceiving the mounting pins, 30022 c, 30016 c, and 30016 d, respectivelyand includes an engagement arm 30024 d. A first trigger 30026 defines amounting hole 30026 a for receiving the mounting pin 30016 e andincludes an engagement arm 30026 b at one end, an engagement member30026 c, and an engagement arm 30026 d at another end.

A second upper toggle link 30028 defines mounting holes, 30028 a and30028 b, for receiving the mounting pins, 30018 a and 30018 b, andincludes a mounting pin 30028 c at one end. A second lower toggle link30030 defines mounting holes, 30030 a, 30030 b, and 30030 c, forreceiving the mounting pins, 30028 c, 30018 c, and 30018 d, respectivelyand includes an engagement arm 30030 d. A second trigger 30032 defines amounting hole 30032 a for receiving the mounting pin 30018 e andincludes an engagement arm 30032 b at one end, an engagement member30032 c, and an engagement arm 30032 d at another end.

An end of a tubular spring housing 30034 that defines a longitudinalpassage 30034 a, mounting holes, 30034 b and 30034 c, and mountingholes, 30034 ba and 30034 ca, and includes an internal flange 30034 dand an internal annular recess 30034 e at one end, and an internalflange 30034 f, an internal annular recess 30034 g, an internal annularrecess 30034 h, and an external threaded connection 30034 i at anotherend receives and mates with the end of the tubular toggle bushing 30008.Mounting screws, 30035 a and 30035 b, are mounted within and coupled tothe mounting holes, 30008 xb and 30008 xa, respectively, of the tubulartoggle bushing 30008 and are received within the mounting holes, 30034ba and 30034 ca, respectively, of the tubular spring housing 30034.

A tubular retracting spring ring 30036 that defines mounting holes,30036 a and 30036 b, receives and mates with a portion of the tubularlower mandrel 30006 and is received within and mates with a portion ofthe tubular spring housing 30034. Mounting screws, 30038 a and 30038 b,are mounted within and coupled to the mounting holes, 30036 a and 30036b, respectively, of the tubular retracting spring ring 30036 and extendinto the mounting holes, 30034 b and 30034 c, respectively, of thetubular spring housing 30034.

Casing diameter sensor springs, 30040 a and 30040 b, are positionedwithin the longitudinal slots, 30008 c and 3008 d, respectively, of thetubular toggle bushing 30008 that engage the engagement members, 30026 cand 30032 c, and engagement arms, 30026 d and 30032 d, of the first andsecond triggers, 30026 and 30032, respectively. An inner flange 30042 aof an end of a tubular spring washer 30042 mates with and receives aportion of the tubular lower mandrel 30006 and an end face of the innerflange of the tubular spring washer is positioned proximate and end faceof the external flange 30006 d of the tubular lower mandrel. The tubularspring washer 30042 is further received within the longitudinal passage30034 a of the tubular spring housing 30034.

An end of a retracting spring 30044 that receives the tubular lowermandrel 30006 is positioned within the tubular spring washer 30042 incontact with the internal flange 30042 a of the tubular spring washerand the other end of the retracting spring is positioned in contact withan end face of the tubular retracting spring ring 30036.

A sealing element 30046 is received within the external annular recess30006 j of the tubular lower mandrel 30006 for sealing the interfacebetween the tubular lower mandrel and the tubular spring housing 30034.A sealing element 30048 is received within the internal annular recess30034 h of the tubular spring housing 30034 for sealing the interfacebetween the tubular spring housing and the tubular lower mandrel 30006.

An internal threaded connection 30050 a of an end of a tubular upperhinge sleeve 30050 that includes an internal flange 30050 b and aninternal pivot 30050 c receives and is coupled to the external threadedconnection 30034 i of the end of the tubular spring housing 30034.

An external flange 30052 a of a base member 30052 b of an upper camassembly 30052, that is mounted upon and receives the lower tubularmandrel 30006, that includes an internal flange 30052 c that is receivedwithin the external annular recess 30006 e of the lower tubular mandrel30006 and a plurality of circumferentially spaced apart tapered cam arms30052 d extending from the base member mates with and is received withinthe tubular upper hinge sleeve 30050. The base member 30052 b of theupper cam assembly 30052 further includes a plurality ofcircumferentially spaced apart teeth 30052 f that mate with and arereceived within a plurality of circumferentially spaced apart teeth30034 j provided on the end face of the tubular spring housing 30034 andan end face of the external flange 30052 a of the base member of theupper cam assembly is positioned in opposing relation to an end face ofthe internal flange 30050 b of the tubular upper hinge sleeve 30050.Each of the cam arms 30052 d of the upper cam assembly 30052 includeexternal cam surfaces 30052 e. In an exemplary embodiment, the teeth30052 f of the base member 30052 b of the upper cam assembly 30052 andthe teeth 30034 j provided on the end face of the tubular spring housing30034 permit torsional loads to be transmitted between the tubularspring housing and the upper cam assembly.

A plurality of circumferentially spaced apart upper expansion segments30054 are mounted upon and receive the lower tubular mandrel 30006 andeach include an external pivot recess 30054 a at one end for mating withand receiving the internal pivot 30050 c of the tubular upper hingesleeve 30050 and an external tapered expansion surface 30054 b atanother end and are pivotally mounted within the tubular upper hingesleeve and are interleaved with the circumferentially spaced apart camarms 30052 d of the upper cam assembly 30052. The upper expansionsegments 30054 are interleaved among the cam arms 30052 d of the uppercam assembly 30052.

A plurality of circumferentially spaced apart lower expansion segments30058 are mounted upon and receive the lower tubular mandrel 30006, areinterleaved among the upper expansion segments 30054, are oriented inthe opposite direction to the upper expansion segments 30054, eachinclude an external pivot recess 30058 a at one end and an externaltapered expansion surface 30054 b at another end and are positioned inopposing relation to corresponding circumferentially spaced apart camarms 30052 d of the upper cam assembly 30052.

A lower cam assembly 30060 is mounted upon and receives the lowertubular mandrel 30006 that includes a base member 30060 a having anexternal flange 30060 b, a plurality of circumferentially spaced apartcam arms 30060 d that extend from the base member that each includeexternal cam surfaces 30060 e and define mounting holes 30060 f and30060 g. The base member 30060 a of the lower cam assembly 30060 furtherincludes a plurality of circumferentially spaced apart teeth 30060 h.The circumferentially spaced apart cam arms 30060 d of the lower camassembly 30060 are interleaved among the lower expansion segments 30058and the circumferentially spaced apart cam arms 30052 d of the upper camassembly 30052 and positioned in opposing relation to correspondingupper expansion segments 30054.

Mounting screws, 30062 a, 30062 b, 30062 c, and 30062 e, are mountedwithin the corresponding mounting holes, 30060 f and 30060 g, of thelower cam assembly 30060 and are received within the external annularrecess 30006 g of the lower cam assembly 30060.

A tubular lower hinge sleeve 30064 that receives the lower expansionsegments 30058 and the lower cam assembly 30060 includes an internalflange 30064 a for engaging the external flange 30060 b of the basemember of the lower cam assembly 30060, an internal pivot 30064 b forengaging and receiving the external pivot recess 30058 a of the lowerexpansion segments 30058 thereby pivotally mounting the lower expansionsegments within the tubular lower hinge sleeve, and an internal threadedconnection 30064 c.

An external threaded connection 30066 a of an end of a tubular sleeve30066 that defines mounting holes, 30066 b and 30066 c, and includes aninternal annular recess 30066 d having a shoulder 30066 e, an internalflange 30066 f, and an internal threaded connection 30066 g at anotherend is received within and coupled to the internal threaded connection30064 c of the tubular lower hinge sleeve 30064. An external threadedconnection 30068 a of an end of a tubular member 30068 that defines alongitudinal passage 30068 b and mounting holes, 30068 c and 30068 d,and includes an external annular recess 30068 e, and an externalthreaded connection 30068 f at another end is received within and iscoupled to the internal threaded connection 30066 g of the tubularsleeve 30066.

Mounting screws, 30070 a and 30070 b, are mounted in and coupled to themounting holes, 30068 c and 30068 d, respectively, of the tubular member30068 that also extend into the mounting holes, 30066 b and 30066 c,respectively, of the tubular sleeve 30066. A sealing element 30072 isreceived within the external annular recess 30068 e of the tubularmember 30068 for sealing the interface between the tubular member andthe tubular sleeve 30066.

An internal threaded connection 30074 a of a tubular retracting piston30074 that defines a longitudinal passage 30074 b and includes aninternal annular recess 30074 c and an external annular recess 30074 dreceives and is coupled to the external threaded connection 30006 i ofthe tubular lower mandrel 30006. A sealing element 30076 is receivedwithin the external annular recess 30074 d of the tubular retractingpiston 30074 for sealing the interface between the tubular retractingpiston and the tubular sleeve 30066. A sealing element 30078 is receivedwithin the internal annular recess 30074 c of the tubular retractingpiston 30074 for sealing the interface between the tubular retractingpiston and the tubular lower mandrel 30006.

Locking dogs 30080 mate with and receive the external teeth 30006 h ofthe tubular lower mandrel 30006. A spacer ring 30082 is positionedbetween an end face of the locking dogs 30080 and an end face of thelower cam assembly 30060. A release piston 30084 mounted upon thetubular lower mandrel 30006 defines a radial passage 30084 a formounting a burst disk 30086 includes sealing elements, 30084 b, 30084 c,and 30084 d. The sealing elements, 30084 b and 30084 d, sealing theinterface between the release piston 30084 and the tubular lower mandrel30006. An end face of the release piston 30084 is positioned in opposingrelation to an end face of the locking dogs 30080.

A release sleeve 30088 that receives and is mounted upon the lockingdogs 30080 and the release piston 30084 includes an internal flange30088 a at one end that sealingly engages the tubular lower mandrel30006. A bypass sleeve 30090 that receives and is mounted upon therelease sleeve 30088 includes an internal flange 30090 a at one end.

In an exemplary embodiment, during operation of the adjustable casingexpansion cone assembly 30, the retracting spring 30044 is compressedand thereby applies a biasing spring force in a direction 30092 from thelower tubular mandrel 30006 to the tubular spring housing 30034 that, inthe absence of other forces, moves and/or maintains the upper camassembly 30052 and the upper expansion segments 30054 out of engagementwith the lower expansion segments 30058 and the lower cam assembly30060. In an exemplary embodiment, during operation of the adjustablebell section expansion cone assembly 28, an external threaded connection20 a of an end of the sealing cup assembly 20 is coupled to the internalthreaded connection 30002 d of the upper tubular tool joint 30002 and aninternal threaded connection 30 a of an end of the adjustable casingexpansion cone assembly 30 is coupled to the external threadedconnection 30068 f of the tubular member 30068.

The upper cam assembly 30052 and the upper expansion segments 30054 maybe brought into engagement with the lower expansion segments 30058 andthe lower cam assembly 30060 by pressurizing an annulus 30094 definedbetween the lower tubular mandrel 30006 and the tubular spring housing30034. In particular, injection of fluidic materials into the adjustablecasing expansion cone assembly 30 through the longitudinal passage 30006b of the lower tubular mandrel 30006 and into the radial passage 30006ba may pressurize the annulus 30094 thereby creating sufficientoperating pressure to generate a force in a direction 30096 sufficientto overcome the biasing force of the retracting spring 30044. As aresult, the spring housing 30034 may be displaced in the direction 30096relative to the lower tubular mandrel 30006 thereby displacing thetubular upper hinge sleeve 30050, upper cam assembly 30052, and upperexpansion segments 30054 in the direction 30096.

In an exemplary embodiment, as illustrated in FIGS. 17P, 17Q, and 17R,the displacement of the upper cam assembly 30052 and upper expansionsegments 30054 in the direction 30096 will cause the lower expansionsegments 30058 to ride up the cam surfaces 30052 e of the cam arms 30052d of the upper cam assembly 30052 while also pivoting about the lowertubular hinge segment 30064, and will also cause the upper expansionsegments 30054 to ride up the cam surfaces 30060 e of the cam arms 30060d of the lower cam assembly 30060 while also pivoting about the uppertubular hinge segment 30050. In an exemplary embodiment, when the upperand lower expansion segments, 30054 and 30058, are brought into axialalignment, they define an outer expansion surface that is approximatelycontiguous in a circumferential direction and which provides an outerexpansion surface that at least approximates a conical surface.

In an exemplary embodiment, during the operation of the adjustablecasing expansion cone assembly 30, when the upper and lower expansionsegments, 30054 and 30058, brought into axial alignment into a radiallyexpanded position, the upper and lower expansion segments, 30054 and30058, are displaced relative to the expandable wellbore casing 100 tothereby radially expand and plastically deform at least a portion of theexpandable wellbore casing. In an exemplary embodiment, during theradial expansion and plastic deformation of the expandable wellborecasing 100, the adjustable casing expansion cone assembly 30 may then berotated relative to the expandable wellbore casing to enhance and/ormodify the rate at which the expandable wellbore casing is radiallyexpanded and plastically deformed.

In an exemplary embodiment, the upper cam assembly 30052 and the upperexpansion segments 30054 may be moved out of engagement with the lowerexpansion segments 30058 and the lower cam assembly 30060 by reducingthe operating pressure within the annulus 30094.

In an alternative embodiment, as illustrated in FIGS. 17S, 17T, 17U and17V, during operation of the adjustable casing expansion cone assembly30, the upper cam assembly 30052 and the upper expansion segments 30054may also be moved out of engagement with the lower expansion segments30058 and the lower cam assembly 30060 by sensing the operating pressurewithin the longitudinal passage 30006 b of the lower tubular mandrel30006. In particular, as illustrated in FIG. 17T, if the operatingpressure within the longitudinal passage 30006 b and radial passage30006 bb of the lower tubular mandrel 30006 exceeds a predeterminedvalue, the burst disc 30086 will open the passage 30084 a therebypressurizing the interior of the tubular release sleeve 30088 therebydisplacing the tubular release sleeve 30088 downwardly in a direction30092 away from engagement with the locking dogs 30080.

As a result, as illustrated in FIG. 17U, the locking dogs 30080 aredisplaced outwardly in the radial directed and thereby released fromengagement with the lower tubular mandrel 30006 thereby permitting thelower expansion segments 30058 and the lower cam assembly 30060 to bedisplaced downwardly relative to the lower tubular mandrel.

As a result, as illustrated in FIG. 17V, the operating pressure withinthe lower tubular mandrel 30066 may then cause the lower tubular mandrelto be displaced downwardly in the direction 30094 relative to thetubular lower mandrel 30006 and the retracting piston 30074. As aresult, the lower tubular mandrel 30066, the lower expansion segments30058, the lower cam assembly 30060, and tubular lower hinge sleeve30064 are displaced downwardly in the direction 30094 relative to thetubular spring housing 30034 thereby moving the lower expansion segments30058 and the lower cam assembly 30060 out of engagement with the uppercam assembly 30052 and the upper expansion segments 30054.

In an exemplary embodiment, as illustrated in FIGS. 17W, 17X, and 17Y,during operation of the adjustable casing expansion cone assembly 30,the adjustable casing expansion cone assembly senses the diameter of theexpandable wellbore casing 100 using the upper toggle links, 30022 and30028, lower toggle links, 30024 and 30030, and triggers, 30026 and30032, and then prevents the engagement of the upper cam assembly 30052and the upper expansion segments 30054 with the lower expansion segments30058 and the lower cam assembly 30060.

In particular, as illustrated in FIG. 17W, anytime the upper togglelinks, 30022 and 30028, and lower toggle links, 30024 and 30030, arepositioned within a portion of the expandable wellbore casing 100 thathas been radially expanded and plastically deformed by the system 10,the triggers, 30026 and 30032, will be pivoted by the engagement arms,30024 d and 30030 d, of the lower toggle links, 30024 and 30030, to aposition in which the triggers will no longer engage the internal flange30034 d of the end of the tubular spring housing 30034 therebypermitting the displacement of the tubular spring housing in thedirection 30096. As a result, the upper cam assembly 30052 and the upperexpansion segments 30054 can be brought into engagement with the lowerexpansion segments 30058 and the lower cam assembly 30060. In anexemplary embodiment, the upper toggle links, 30022 and 30028, and thelower toggle links, 30024 and 30030, are spring biased towards theposition illustrated in FIG. 17W.

Conversely, as illustrated in FIG. 17X, anytime the upper toggle links,30022 and 30028, and lower toggle links, 30024 and 30030, are positionedwithin a portion of the expandable wellbore casing 100 that has not beenradially expanded and plastically deformed by the system 10, thetriggers, 30026 and 30032, will be maintained in a position in which thetriggers will engage the internal flange 30034 d of the end of thetubular spring housing 30034 thereby preventing the displacement of thetubular spring housing in the direction 30096. As a result, the uppercam assembly 30052 and the upper expansion segments 30054 cannot bebrought into engagement with the lower expansion segments 30058 and thelower cam assembly 30060. In an exemplary embodiment, the triggers,30026 and 30032, are spring biased towards the position illustrated inFIG. 17X.

In an exemplary embodiment, as illustrated in FIG. 17Y, the tubularspring housing 30034 may be displaced upwardly in the direction 30098even if the upper toggle links, 30022 and 30028, and lower toggle links,30024 and 30030, are positioned within a portion of the expandablewellbore casing 100 that has not been radially expanded and plasticallydeformed by the system 10.

In an exemplary embodiment, as illustrated in FIGS. 17Z1 to 17Z4, 17AA1to 17AA4, 17AB1 to 17AB4, 17AC1 to 17AC4, 17AD, and 17AE, the tubularspring housing 30034 of the adjustable casing expansion cone assembly 30defines internal annular recesses 30034 k and 30034 l, spaced apart byan internal flange 30034 m, the tubular toggle bushing 30008 defines anexternal annular recess 30008 ac, and the adjustable casing expansioncone assembly further includes pins, 30100 a and 30100 b and 30102 a and30102 b, mounted in holes 30008 j and 30008 o and 30008 k and 30008 n,respectively, of the tubular toggle bushing, and a one-shot deactivationdevice 30104 mounted on the tubular toggle bushing between the pins,30100 a and 30100 b and 30102 a and 30102 b.

The one-shot deactivation device 30104 includes a tubular body 30104 athat defines radial holes, 30104 b and 30014 c, and includes an externalannular recess 30104 d at one end, a centrally positioned externalflange 30104 e, a centrally positioned internal annular recess 30104 f,and an external annular recess 30104 g at another end. An engagementmember 30106 that includes a base member 30106 a having a tapered end30106 b and a key member 30106 c having a tapered end 30106 d isreceived within a portion of the internal annular recess 30104 f of thetubular body 30104 a and an engagement member 30108 that includes a basemember 30108 a having a tapered end 30108 b and a key member 30108 chaving a tapered end 30108 d is received within an opposite portion ofthe internal annular recess 30104 f of the tubular body 30104 a. Springmembers, 30110 and 30112, are received within the annular recess 30104 fof the tubular body 30104 a for biasing the base members, base member30106 a and 30108 a, of the engagement members, 30106 and 30108,respectively, radially inwardly relative to the tubular body 30104 a.

In an exemplary embodiment, during operation of the adjustable bellsection expansion cone assembly 28, as illustrated in FIG. 17Z, theone-shot deactivation device 30104 are positioned proximate and inintimate contact with the pins, 30102 a and 30102 b, with the taperedends, 30106 b and 30108 b, of the base members, 30106 a and 30108 a, ofthe engagement members, 30106 and 30108, received within the externalannular recess 30008 ac of the tubular toggle bushing 30008. When theone-shot deactivation device 30104 is positioned as illustrated in FIG.17Z, the external annular recess 30104 d of the tubular body 30104 a ofthe one-shot deactivation device is moved out of engagement with theengagement arms, 30026 d and 30032 d, of the triggers, 30026 and 30032,respectively. As a result, the triggers, 30026 and 30032, may operatenormally as described above with reference to FIGS. 17W, 17X, and 17Y.

Conversely, in an exemplary embodiment, during operation of theadjustable casing expansion cone assembly 30, as illustrated in FIGS.17AA1 to 17AA4, the one-shot deactivation device 30104 are positionedproximate and in intimate contact with the pins, 30100 a and 30100 b,with the tapered ends, 30106 b and 30108 b, of the base members, 30106 aand 30108 a, of the engagement members, 30106 and 30108, not receivedwithin the external annular recess 30008 ac of the tubular togglebushing 30008. When the one-shot deactivation device 30104 is positionedas illustrated in FIGS. 17AA1 to 17AA4, the external annular recess30104 d of the tubular body 30104 a of the one-shot deactivation deviceis moved into engagement with the engagement arms, 30026 d and 30032 d,of the triggers, 30026 and 30032, respectively. As a result, thetriggers, 30026 and 30032, are deactivated and may not operate normallyas described above with reference to FIGS. 17W, 17X, and 17Y.

In an alternative embodiment, the elements of the adjustable casingexpansion cone assembly 30 that sense the diameter of the expandablewellbore casing 100 may be disabled or omitted or adjusted to sense anypre-selected internal diameter of the expandable wellbore casing.

In an exemplary embodiment, as illustrated in 18A to 18C, the packersetting tool assembly 32 includes a tubular adaptor 3202 that defines alongitudinal passage 3202 a, radial external mounting holes, 3202 b and3202 c, radial passages, 3202 d and 3202 e, and includes an externalthreaded connection 3202 f at one end and an internal annular recess3202 g having an internal threaded connection at another end. Anexternal threaded connection 3204 a of an end of a tubular upper mandrel3204 that defines a longitudinal passage 3204 b, internally threadedexternal mounting holes, 3204 c and 3204 d, and includes an externalannular recess 3204 e, external annular recess 3204 f, external annularrecess 3204 g, external flange 3204 h, external splines 3204 i, and aninternal threaded connection 3204 j at another end is received withinand is coupled to the internally threaded connection of the internalannular recess 3202 g of the other end of the tubular adaptor 3202.Mounting screws, 3205 a and 3205 b, are received within and coupled tothe mounting holes, 3204 c and 3204 d, of the tubular upper mandrel 3204that also extend into the radial passages, 3202 d and 3202 e, of thetubular adaptor 3202.

An external threaded connection 3206 a of an end of a mandrel 3206 thatdefines a longitudinal passage 3206 b and includes an external annularrecess 3206 c and an external annular recess 3206 d having an externalthreaded connection is received within and is coupled to the internalthreaded connection 3204 j of the tubular upper mandrel 3204. Aninternal threaded connection 3208 a of a tubular stinger 3208 thatdefines a longitudinal passage 3208 b and includes an external annularrecess 3208 c, and an external tapered annular recess 3208 d and anengagement shoulder 3208 e at another end receives and is coupled to theexternal threaded connection of the external annular recess 3206 d ofthe mandrel 3206. A sealing member 3210 is mounted upon and coupled tothe external annular recess 3206 d of the mandrel 3206.

An internal flange 3212 a of a tubular key 3212 that includes anexternal annular recess 3212 b at one end and an internal annular recess3212 c at another end is movably received within and engages theexternal annular recess 3204 f of the tubular upper mandrel 3204. Agarter spring 3214 is received within and engages the external annularrecess 3212 b of the tubular key 3212.

An end of a tubular bushing 3216 that defines a longitudinal passage3216 a for receiving and mating with the upper mandrel 3204, and radialpassages, 3216 b and 3216 c, and includes an external threadedconnection 3216 d at an intermediate portion, and an external flange3216 e, an internal annular recess 3216 f, circumferentially spacedapart teeth 3216 g, and external flanges, 3216 h and 3216 i, at anotherend is received within and mates with the internal annular recess 3212 cof the tubular key 3212. An internal threaded connection 3218 a of atubular drag block body 3218 that defines a longitudinal passage 3218 bfor receiving the tubular bushing 3216, mounting holes, 3218 c and 3218d, mounting holes, 3218 e and 3218 f, and includes an internal threadedconnection 3218 g at one end, a centrally positioned external annularrecess 3218 h, and an external threaded connection 3218 i at another endis received within and coupled to the external threaded connection 3216d of the tubular bushing 3216.

A first tubular keeper 3220 that defines mounting holes, 3220 a and 3220b, is coupled to an end of the tubular drag block body 3218 by mountingscrews, 3222 a and 3222 b, that are received within and are coupled tothe mounting holes, 3218 c and 3218 d, of the tubular drag block body. Asecond tubular keeper 3224 that defines mounting holes, 3224 a and 3224b, is coupled to an end of the tubular drag block body 3218 by mountingscrews, 3226 a and 3226 b, that are received within and are coupled tothe mounting holes, 3218 e and 3218 f, of the tubular drag block body.

Drag blocks, 3228 and 3230, that are received within the externalannular recess 3218 h of the tubular drag block body 3218, include endsthat mate with and are received within the end of the first tubularkeeper 3220, and other ends that mate with and are received within theend of the second tubular keeper 3224. The drag blocks, 3228 and 3230,further include internal annular recesses, 3228 a and 3230 a,respectively, that receive and mate with ends of springs, 3232 and 3234,respectively. The springs, 3232 and 3234, also receive and mate with theexternal annular recess 3218 h of the tubular drag block body 3218.

An external threaded connection 3236 a of an end of a tubular releasingcap extension 3236 that defines a longitudinal passage 3236 b andincludes an internal annular recess 3236 c and an internal threadedconnection 3236 d at another end is received within and is coupled tothe internal threaded connection 3218 g of the tubular drag block body3218. An external threaded connection 3238 a of an end of a tubularreleasing cap 3238 that defines a longitudinal passage 3238 b andincludes an internal annular recess 3238 c is received within andcoupled to the internal threaded connection 3236 d of the tubularreleasing cap extension 3236. A sealing element 3240 is received withinthe internal annular recess 3238 c of the tubular releasing cap 3238 forfluidicly sealing the interface between the tubular releasing cap andthe upper mandrel 3204.

An internal threaded connection 3242 a of an end of a tubular settingsleeve 3242 that defines a longitudinal passage 3242 b, radial passage3242 c, radial passages, 3242 d and 3242 e, radial passage 3242 f, andincludes an internal flange 3242 g at another end receives the externalthreaded connection 3218 i of the tubular drag block body 3218. Aninternal flange 3244 a of a tubular coupling ring 3244 that defines alongitudinal passage 3244 b and radial passages, 3244 c and 3244 d,receives and mates with the external flange 3216 h of the tubularbushing 3216 and an end face of the internal flange of the tubularcoupling ring is positioned proximate and in opposing relation to an endface of the external flange 3216 i of the tubular bushing.

An internal flange 3246 a of a tubular retaining collet 3246 thatincludes a plurality of axially extending collet fingers 3246 b, eachhaving internal flanges 3246 c at an end of each collet finger, forengaging and receiving the tubular coupling ring 3244 receives and mateswith external flange 3216 e of the tubular bushing 3216 and an end faceof the internal flange of the tubular retaining collet is positionedproximate and in opposing relation to an end face of the external flange3216 h of the tubular bushing.

In an exemplary embodiment, the packer assembly 36 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application serial number PCT/US03/14153,filed on Nov. 13, 2003, and/or (2) PCT patent application serial numberPCT/US03/29460, filed on Sep. 23, 2003, and/or (3) PCT patentapplication serial number PCT/US04/07711, filed on Mar. 11, 2004, and/or(4) PCT patent application serial number PCT/US04/09434, filed on Mar.26, 2004, and/or (5) PCT patent application serial numberPCT/US04/10317, filed on Apr. 2, 2004, and/or (6) PCT patent applicationserial number PCT/US04/10712, filed on Apr. 7, 2004, and/or (7) PCTpatent application serial number PCT/US04/10762, filed on Apr. 6, 2004,the disclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 19-1 to 19-5, thepacker assembly 36 includes a tubular upper adaptor 3602 that defines alongitudinal passage 3602 a having a tapered opening 3602 b and mountingholes, 3602 c and 3602 d, that includes a plurality of circumferentiallyspaced apart teeth 3602 e at one end, an external flange 3602 f, and aninternal threaded connection 3602 g at another end. In an exemplaryembodiment, the tubular upper adaptor 3602 is fabricated from aluminum.An external threaded connection 3604 a of an end of a tubular uppermandrel 3604 that defines a longitudinal passage 3604 b, mounting holes,3604 c and 3604 d, mounting holes, 3604 e and 3604 f, and mountingholes, 3604 g and 3604 h, and includes an external flange 3604 i, aninternal annular recess 3604 j, and an internal threaded connection 3604k at another end is received within and coupled to the internal threadedconnection 3602 g of the tubular upper adaptor 3602. In an exemplaryembodiment, the tubular upper mandrel 3604 is fabricated from aluminum.

An upper tubular spacer ring 3606 that defines mounting holes, 3606 aand 3606 b, receives and mates with the end of the tubular upper mandrel3604 and includes an angled end face 3606 c and another end face that ispositioned proximate to an end face of the tubular upper adaptor 3602 iscoupled to the tubular upper mandrel by shear pins, 3608 a and 3608 b,that are mounted within and coupled to the mounting holes, 3604 c and3606 a, and, 3604 d and 3606 b, respectively, of the tubular uppermandrel and upper tubular spacer ring, respectively. A lower tubularspacer ring 3610 that includes an angled end face 3610 a receives,mates, and is coupled to the other end of the tubular upper mandrel 3604and includes another end face that is positioned proximate to an endface of the external flange 3604 i of the tubular upper mandrel 3604. Inan exemplary embodiment, the upper and tubular spacer rings, 3606 and3610, are fabricated from a composite material.

An upper tubular slip 3612 that receives and is movably mounted upon thetubular upper mandrel 3604 defines a longitudinal passage 3612 a havinga tapered opening 3612 b and includes external annular recesses, 3612 c,3612 d, 3612 e, 3612 f, and 3612 g, and an angled end face 3612 h thatmates with and is positioned proximate the angled end face 3606 c of theupper tubular spacer ring 3606. Slip retaining bands, 3614 a, 3614 b,3614 c, 3614 d, and 3614 e, are received within and coupled to theexternal annular recesses, 3612 c, 3612 d, 3612 e, 3612 f, and 3612 g,of the upper tubular slip 3612. A lower tubular slip 3616 that receivesand is movably mounted upon the tubular upper mandrel 3604 defines alongitudinal passage 3616 a having a tapered opening 3616 b and includesexternal annular recesses, 3616 c, 3616 d, 3616 e, 3616 f, and 3616 g,and an angled end face 3616 h that mates with and is positionedproximate the angled end face 3610 a of the lower tubular spacer ring3610. Slip retaining bands, 3618 a, 3618 b, 3618 c, 3618 d, and 3618 e,are received within and coupled to the external annular recesses, 3616c, 3616 d, 3616 e, 3616 f, and 3616 g, of the lower tubular slip 3616.In an exemplary embodiment, the upper and lower tubular slips, 3612 and3616, are fabricated from composite materials, and at least some of theslip retaining bands, 3614 a, 3614 b, 3614 c, 3614 d, 3614 e, 3618 a,3618 b, 3618 c, 3618 d, and 3618 e are fabricated from carbide insertmaterials.

An upper tubular wedge 3620 that defines an longitudinal passage 3620 afor receiving the tubular upper mandrel 3604 and mounting holes, 3620 band 3620 c, and includes an angled end face 3620 d at one end that isreceived within and mates with the tapered opening 3612 b of the uppertubular slip 3612, and an angled end face 3620 e at another end iscoupled to the tubular upper mandrel by shear pins, 3622 a and 3622 b,mounted within and coupled to the mounting holes, 3604 e and 3620 b,and, 3604 f and 3620 c, respectively, of the tubular upper mandrel andupper tubular wedge, respectively. A lower tubular wedge 3624 thatdefines an longitudinal passage 3624 a for receiving the tubular uppermandrel 3604 and mounting holes, 3624 b and 3624 c, and includes anangled end face 3624 d at one end that is received within and mates withthe tapered opening 3616 b of the lower tubular slip 3616, and an angledend face 3624 e at another end is coupled to the tubular upper mandrelby shear pins, 3626 a and 3626 b, mounted within and coupled to themounting holes, 3604 g and 3624 b, and, 3604 h and 3624 c, respectively,of the tubular upper mandrel and lower tubular wedge, respectively. Inan exemplary embodiment, the upper and lower tubular wedges, 3620 and3624, are fabricated from composite materials.

An upper tubular extrusion limiter 3628 that defines a longitudinalpassage 3628 a for receiving the tubular upper mandrel 3604 includes anangled end face 3628 b at one end that mates with the angled end face3620 e of the upper tubular wedge 3620, an angled end face 3628 c atanother end having recesses 3628 d, and external annular recesses, 3628e, 3628 f and 3628 g. Retaining bands, 3630 a, 3630 b, and 3630 c, aremounted within and coupled to the external annular recesses, 3628 e,3628 f and 3628 g, respectively, of the upper tubular extrusion limiter3628. Circular disc-shaped extrusion preventers 3632 are coupled andmounted within the recesses 3628 d. A lower tubular extrusion limiter3634 that defines a longitudinal passage 3634 a for receiving thetubular upper mandrel 3604 includes an angled end face 3634 b at one endthat mates with the angled end face 3624 e of the lower tubular wedge3624, an angled end face 3634 c at another end having recesses 3634 d,and external annular recesses, 3634 e, 3634 f and 3634 g. Retainingbands, 3636 a, 3636 b, and 3636 c, are mounted within and coupled to theexternal annular recesses, 3634 e, 3634 f and 3634 g, respectively, ofthe lower tubular extrusion limiter 3634. Circular disc-shaped extrusionpreventers 3638 are coupled and mounted within the recesses 3634 d. Inan exemplary embodiment, the upper and lower extrusion limiters, 3628and 3634, are fabricated from composite materials.

An upper tubular elastomeric packer element 3640 that defines alongitudinal passage 3640 a for receiving the tubular upper mandrel 3604includes an angled end face 3640 b at one end that mates with and ispositioned proximate the angled end face 3628 c of the upper tubularextrusion limiter 3628 and an curved end face 3640 c at another end. Alower tubular elastomeric packer element 3642 that defines alongitudinal passage 3642 a for receiving the tubular upper mandrel 3604includes an angled end face 3642 b at one end that mates with and ispositioned proximate the angled end face 3634 c of the lower tubularextrusion limiter 3634 and an curved end face 3642 c at another end.

A central tubular elastomeric packer element 3644 that defines alongitudinal passage 3644 a for receiving the tubular upper mandrel 3604includes a curved outer surface 3644 b for mating with and engaging thecurved end faces, 3640 c and 3642 c, of the upper and lower tubularelastomeric packer elements, 3640 and 3642, respectively.

An external threaded connection 3646 a of a tubular lower mandrel 3646that defines a longitudinal passage 3646 b having throat passages, 3646c and 3646 d, and flow ports, 3646 e and 3646 f, and a mounting hole3646 g, and includes an internal annular recess 3646 h at one end, andan external flange 3646 i, internal annular recess 3646 j, and internalthreaded connection 3646 k at another end. In an exemplary embodiment,the tubular lower mandrel 3646 is fabricated from aluminum. A, sealingelement 3648 is received within the inner annular recess 3604 j of theother end of the tubular upper mandrel 3604 for sealing an interfacebetween the tubular upper mandrel and the tubular lower mandrel 3646.

A tubular sliding sleeve valve 3650 that defines a longitudinal passage3650 a and radial flow ports, 3650 b and 3650 c, and includes colletfingers 3650 d at one end for engaging the internal annular recess 3646h of the lower tubular mandrel 3646, an external annular recess 3650 e,an external annular recess 3650 f, an external annular recess 3650 g,and circumferentially spaced apart teeth 3650 h at another end isreceived within and is slidably coupled to the longitudinal passage 3646b of the tubular lower mandrel 3646. In an exemplary embodiment, thetubular sliding sleeve valve 3650 is fabricated from aluminum. A setscrew 3652 is mounted within and coupled to the mounting hole 3646 g ofthe tubular lower mandrel 3646 that is received within the externalannular recess 3650 e of the tubular sliding sleeve 3650. Sealingelements, 3654 and 3656, are mounted within the external annularrecesses, 3650 f and 3650 g, respectively, of the tubular sliding sleevevalve 3650 for sealing an interface between the tubular sliding sleevevalve and the tubular lower mandrel 3646.

An end of a tubular outer sleeve 3658 that defines a longitudinalpassage 3658 a, radial passages, 3658 b and 3658 c, upper flow ports,3658 d and 3658 e, lower flow ports, 3658 f and 3658 g, and radialpassages, 3658 h and 36581, receives, mates with, and is coupled to theother end of the tubular upper mandrel 3604 and an end face of the endof the tubular outer sleeve is positioned proximate and end face of thelower tubular spacer ring 3610. The other end of the tubular outersleeve 3658 receives, mates with, and is coupled to the other end of thetubular lower mandrel 3646.

An external threaded connection 3660 a of an end of a tubular bypassmandrel 3660 that defines a longitudinal passage 3660 b, upper flowports, 3660 c and 3660 d, lower flow ports, 3660 e and 3660 f, and amounting hole 3660 g and includes an internal annular recess 3660 h andan external threaded connection 3660 i at another end is received withinand coupled to the internal threaded connection 3646 k of the tubularlower mandrel 3646. A sealing element 3662 is received within theinternal annular recess 3646′ of the tubular lower mandrel 3646 forsealing an interface between the tubular lower mandrel and the tubularbypass mandrel 3660.

A tubular plug seat 3664 that defines a longitudinal passage 3664 ahaving a tapered opening 3664 b at one end, and flow ports, 3664 c and3664 d, and includes an external annular recess 3664 e, an externalannular recess 3664 f, an external annular recess 3664 g, an externalannular recess 3664 h, and an external annular recess 3664 i having anexternal threaded connection at another end is received within and ismovably coupled to the longitudinal passage 3660 b of the tubular bypassmandrel 3660. A tubular nose 3666 is threadably coupled to and mountedupon the external annular recess 3664 i of the tubular plug seat 3664.In an exemplary embodiment, the tubular plug seat 3664 is fabricatedfrom aluminum. Sealing elements, 3668, 3670, and 3672, are receivedwithin the external annular recesses, 3664 e, 3664 g, and 3664 h,respectively, of the tubular plug seat 3664 for sealing an interfacebetween the tubular plug seat and the tubular bypass mandrel 3660. A setscrew 3674 is mounted within and coupled to the mounting hole 3660 g ofthe tubular bypass mandrel 3660 that is received within the externalannular recess 3664 f of the tubular plug seat 3664.

An end of a tubular bypass sleeve 3676 that defines a longitudinalpassage 3676 a and includes an internal annular recess 3676 b at one endand an internal threaded connection 3676 c at another end is coupled tothe other end of the tubular outer sleeve 3658 and mates with andreceives the tubular bypass mandrel 3660. In an exemplary embodiment,the tubular bypass sleeve 3676 is fabricated from aluminum.

An external threaded connection 3678 a of a tubular valve seat 3678 thatdefines a longitudinal passage 3678 b including a valve seat 3678 c andup-jet flow ports, 3678 d and 3678 e, and includes a spring retainer3678 f and an external annular recess 3678 g is received within and iscoupled to the internal threaded connection 3676 c of the tubular bypasssleeve 3676. In an exemplary embodiment, the tubular valve seat 3678 isfabricated from aluminum. A sealing element 3680 is received within theexternal annular recess 3678 g of the tubular valve seat 3678 forfluidicly sealing an interface between the tubular valve seat and thetubular bypass sleeve 3676.

A poppet valve 3682 mates with and is positioned within the valve seat3678 c of the tubular valve seat 3678. An end of the poppet valve 3682is coupled to an end of a stem bolt 3684 that is slidingly supported forlongitudinal displacement by the spring retainer 3678 f A valve spring3686 that surrounds a portion of the stem bolt 3684 is positioned inopposing relation to the head of the stem bolt and a support 3678 fa ofthe spring retainer 3678 f for biasing the poppet valve 3682 intoengagement with the valve seat 3678 c of the tubular valve seat 3678.

An end of a composite nose 3688 that defines a longitudinal passage 3688a and mounting holes, 3688 b and 3688 c, and includes an internalthreaded connection 3688 d at another end receives, mates with, and iscoupled to the other end of the tubular valve seat 3678. A tubular nosesleeve 3690 that defines mounting holes, 3690 a and 3690 b, is coupledto the composite nose 3688 by shear pins, 3692 a and 3692 b, that aremounted in and coupled to the mounting holes, 3688 b and 3690 a, and,3688 c and 3690 b, respectively, of the composite nose and tubular nosesleeve, respectively.

An external threaded connection 3694 a of a baffle nose 3694 thatdefines longitudinal passages, 3694 b and 3694 c, is received within andis coupled to the internal threaded connection internal threadedconnection 3688 d of the composite nose 3688.

In an exemplary embodiment, as illustrated in FIGS. 19A1 to 19A5, duringthe operation of the packer setting tool assembly 32 and packer assembly36, the packer setting tool and packer assembly are coupled to oneanother by inserting the end of the tubular upper adaptor 3602 into theother end of the tubular coupling ring 3244, bringing thecircumferentially spaced teeth 3216 g of the other end of the tubularbushing 3216 into engagement with the circumferentially spaced teeth3602 e of the end of the tubular upper adaptor, and mounting shear pins,36100 a and 36100 b, within the mounting holes, 3244 c and 3602 c, and,3244 d and 3602 d, respectively, of the tubular coupling ring andtubular upper adaptor, respectively. As a result, the tubular mandrel3206 and tubular stinger 3208 of the packer setting tool assembly 32 arethereby positioned within the longitudinal passage 3604 a of the tubularupper mandrel 3604 with the 3208 e of the tubular stinger positionedwithin the longitudinal passage 3646 b of the tubular lower mandrel 3646proximate the collet fingers 3650 d of the tubular sliding sleeve valve3650.

Furthermore, in an exemplary embodiment, during the operation of thepacker setting tool 32 and packer assembly 36, as illustrated in FIGS.20A1 to 20A5, the packer setting tool and packer assembly are positionedwithin the expandable wellbore casing 100 and an internal threadedconnection 30 a of an end of the adjustable casing expansion coneassembly 30 receives and is coupled to the external threaded connection3202 f of the end of the tubular adaptor 3202 of the packer setting toolassembly. Furthermore, shear pins, 36102 a and 36102 b, mounted withinthe mounting holes, 3658 b and 3658 c, of the tubular outer sleeve 3658couple the tubular outer sleeve to the expandable wellbore casing. As aresult, torsion loads may transferred between the tubular outer sleeve3658 and the expandable wellbore casing 100.

In an exemplary embodiment, as illustrated in FIGS. 20B1 to 20B5, aconventional plug 36104 is then injected into the setting tool assembly32 and packer assembly 36 by injecting a fluidic material 36106 into thesetting tool assembly and packer assembly through the longitudinalpassages, 3202 a, 3204 b, 3206 b, 3208 b, 3650 a, 3646 a, 3660 b, and3664 a of the tubular adaptor 3202, tubular upper mandrel 3204, tubularmandrel 3206, tubular stinger 3208, tubular sliding sleeve valve 3650,tubular lower mandrel 3646, tubular bypass mandrel 3660, and tubularplug seat 3664, respectively. The plug 36104 is thereby positionedwithin the longitudinal passage 3664 a of the tubular plug seat 3664.Continued injection of the fluidic material 36106 following the seatingof the plug 1606 within the longitudinal passage 3664 a of the tubularplug seat 3664 causes the plug and the tubular plug seat to be displaceddownwardly in a direction 36108 until further movement of the tubularplug seat is prevented by interaction of the set screw 3674 with theexternal annular recess 3664 f of the tubular plug seat. As a result,the flow ports, 3664 c and 3664 d, of the tubular plug seat 3664 aremoved out of alignment with the upper flow ports, 3660 c and 3660 d, ofthe tubular bypass mandrel 3660.

In an exemplary embodiment, as illustrated in FIGS. 20C1 to 20C5, afterthe expandable wellbore casing 100 has been radially expanded andplastically deformed to form at least the bell section 112 of theexpandable wellbore casing 100 thereby shearing the shear pins, 36102 aand 36102 b, the setting tool assembly 32 and packer assembly 36 arethen moved upwardly to a position within the expandable wellbore casing100 above the bell section. The tubular adaptor 3202 is then rotated, byrotating the tool string of the system 10 above the setting toolassembly 32, to displace and position the drag blocks, 3228 and 3230,into engagement with the interior surface of the expandable wellborecasing 100.

As a result of the engagement of the drag blocks, 3228 and 3230, withthe interior surface of the expandable wellbore casing 100, furtherrotation of the drag blocks relative to the wellbore casing isprevented. Consequently, due to the operation and interaction of thethreaded connections, 3216 d and 3218 a, of the tubular bushing 3216 andtubular drag block body 3218, respectively, further rotation of thetubular adaptor 3202 causes the tubular drag block body and settingsleeve 3242 to be displaced downwardly in a direction 36112 relative tothe remaining elements of the setting tool assembly 32 and packerassembly 36. As a result, the setting sleeve 3242 engages and displacesthe upper tubular spacer ring 3606 thereby shearing the shear pins, 3622a and 3622 b, and driving the upper tubular slip 3612 onto and up theangled end face 3620 d of the upper tubular wedge 3620 and intoengagement with the interior surface of the expandable wellbore casing100. As a result, longitudinal displacement of the upper tubular slip3612 relative to the expandable wellbore casing 100 is prevented.Furthermore, as a result, the 3246 b collet fingers of the tubularretaining collet 3246 are disengaged from the tubular upper adaptor3602.

In an alternative embodiment, after the drag blocks, 3228 and 3230,engage the interior surface of the expandable wellbore casing 100, anupward tensile force is applied to the tubular support member 12, andthe ball gripper assembly 16 is then operate to engage the interiorsurface of the expandable wellbore casing. The tension actuator assembly18 is then operated to apply an upward tensile force to the tubularadaptor 3202 thereby pulling the upper tubular spacer ring 3606, lowertubular spacer ring 3610, upper tubular slip 3612, lower tubular slip3616, upper tubular wedge 3620, lower tubular wedge 3624, upper tubularextrusion limiter 3628, lower tubular extrusion limiter 3634, andcentral tubular elastomeric element 3644 upwardly into contact with the3242 thereby compressing the upper tubular spacer ring, lower tubularspacer ring, upper tubular slip, lower tubular slip, upper tubularwedge, lower tubular wedge, upper tubular extrusion limiter, lowertubular extrusion limiter, and central tubular elastomeric element. As aresult, the upper tubular slip 3612, lower tubular slip 3616, andcentral tubular elastomeric element 3644 engage the interior surface ofthe expandable wellbore casing 100.

In an exemplary embodiment, as illustrated in FIGS. 20D1 to 20D5, anupward tensile force is then applied to the tubular adaptor 3202 therebycompressing the lower tubular slip 3616, lower tubular wedge 3624,central elastomeric packer element 3644, upper tubular extrusion limiter3628, and upper tubular wedge 3620 between the lower tubular spacer ring3610 and the stationary upper tubular slip 3612. As a result, the lowertubular slip 3616 is driven onto and up the angled end face 3624 d ofthe lower tubular wedge 3624 and into engagement with the interiorsurface of the expandable wellbore casing 100, and the centralelastomeric packer element 3644 is compressed radially outwardly intoengagement with the interior surface of the expandable tubular member.As a result, further longitudinal displacement of the upper tubular slip3612, lower tubular slip 3616, and central elastomeric packer element3644 relative to the expandable wellbore casing 100 is prevented.

In an exemplary embodiment, as illustrated in FIGS. 20E1 to 20E6,continued application of the upward tensile force to tubular adaptor3202 will then shear the shear pins, 1602 a and 1602 b, therebydisengaging the setting tool assembly 32 from the packer assembly 36.

In an exemplary embodiment, as illustrated in FIGS. 20F1 to 20F6, withthe drag blocks, 3228 and 3230, in engagement with the interior surfaceof the expandable wellbore casing 100, the tubular adaptor 102 isfurther rotated thereby causing the tubular drag block body 3218 andsetting sleeve 3242 to be displaced further downwardly in the direction36113 until the tubular drag block body and setting sleeve aredisengaged from the tubular stinger 3208. As a result, the tubularstinger 3208 of the setting tool assembly 32 may then be displaceddownwardly into complete engagement with the tubular sliding sleevevalve 3650.

In an exemplary embodiment, as illustrated in FIGS. 20G1 to 20G6, afluidic material 36114 is then injected into the setting tool assembly32 and the packer assembly 36 through the longitudinal passages 3202 a,3204 b, 3206 b, 3208 b, 3604 b, 3650 a, and 3646 b of the tubularadaptor 3202, tubular upper mandrel 3204, tubular mandrel 3206, tubularstinger 3208, tubular upper mandrel 3604, tubular sliding sleeve valve3650, and tubular lower mandrel 3646, respectively. Because, the plug36104 is seated within and blocks the longitudinal passage 3664 a of thetubular plug seat 3664, the longitudinal passages 3604 b, 3650 a, and3646 b of the tubular upper mandrel 3604, tubular sliding sleeve valve3650, and tubular lower mandrel 3646 are pressurized thereby displacingthe tubular upper adaptor 3602 and tubular upper mandrel 3604 downwardlyuntil the end face of the tubular upper mandrel impacts the end face ofthe upper tubular spacer ring 3606.

In an exemplary embodiment, as illustrated in FIGS. 20H1 to 20H5, thesetting tool assembly 32 is brought back into engagement with the packerassembly 36 until the engagement shoulder 3208 e of the other end of thetubular stinger 3208 engages the collet fingers 3650 d of the end of thetubular sliding sleeve valve 3650. As a result, further downwarddisplacement of the tubular stinger 3208 displaces the tubular slidingsleeve valve 3650 downwardly until the radial flow ports, 3650 b and3650 c, of the tubular sliding sleeve valve are aligned with the flowports, 3646 e and 3646 f, of the tubular lower mandrel 3646. Ahardenable fluidic sealing material 36116 may then be injected into thesetting tool assembly 32 and the packer assembly 36 through thelongitudinal passages 3202 a, 3204 b, 3206 b, 3208 b, and 3650 a of thetubular adaptor 3202, tubular upper mandrel 3204, tubular mandrel 3206,tubular stinger 3208, and tubular sliding sleeve valve 3650,respectively. The hardenable fluidic sealing material may then flow outof the packer assembly 36 through the upper flow ports, 3658 d and 3658e, into the annulus between the expandable wellbore casing 100 and thewellbore 102.

The tubular sliding sleeve valve 3650 may then be returned to itsoriginal position, with the radial flow ports, 3650 b and 3650 c, of thetubular sliding sleeve valve out of alignment with the flow ports, 3646e and 3646 f, of the tubular lower mandrel 3646. The hardenable fluidicsealing material 36116 may then be allowed to cure before, during, orafter the continued operation of the system 10 to further radiallyexpand and plastically deform the expandable wellbore casing.

In an alternative embodiment, as illustrated in FIGS. 21 and 21A to21AX, the packer assembly 36 includes an upper tubular spacer ring 36200receives and mates with the end of the tubular upper mandrel 3604 andincludes an angled end face 36200 a that includes a plurality of spacedapart radial grooves 36200 b and another end face that is positionedproximate to an end face of the tubular upper adaptor 3602 is coupled tothe tubular upper mandrel by shear pins, 36202 a, 36202 b, 36202 c, and36202 d. A lower tubular spacer ring 36204 that includes an angled endface 36204 a that includes a plurality of spaced apart radial grooves36204 b receives, mates, and is coupled to the other end of the tubularupper mandrel 3604 and includes another end face that is positionedproximate to an end face of the external flange 3604 i of the tubularupper mandrel 3604. In an exemplary embodiment, the upper and tubularspacer rings, 3606 and 3610, are fabricated from a composite material.

An upper tubular slip assembly 36206 that receives and is movablymounted upon the tubular upper mandrel 3604 includes a plurality ofsubstantially identical slip elements 36206 a that each include anexterior arcuate cylindrical surface 36206 aa including mounting holes,36206 ab, 36206 ac, 36206 ad, 36206 ae, 36206 af, 36206 ag, 36206 ah,36206 ai, and 36206 aj, and grooves, 36206 aj and 36206 ak, a front endface 36206 a 1, a rear end face 36206 am including a mounting hole 36206an, side faces, 36206 ao and 36206 ap, an interior arcuate cylindricalsurface 36206 aq that mates with the exterior surface of the tubularupper mandrel 3604, and an interior tapered surface 36206 ar including amounting hole 36206 as. Mounting pins 36206 at are received within andcoupled to the mounting holes 36206 an and are received withincorresponding radial grooves 36200 b of the angled end face 36200 a ofthe upper tubular spacer ring 36200. Retaining pins 36206 au are mountedwithin and coupled to the mounting holes 36206 as that include heads36206 av. Slip retaining bands, 36206 aw and 36206 ax, are receivedwithin and coupled to grooves, 36206 aj and 36206 ak, respectively, ofthe slip elements 36206 a. Slip gripping elements, 36206 ay, 36206 az,36206 aaa, 36206 aab, 36206 aac, 36206 aad, 36206 aae, 36206 aaf, and36206 aag, are mounted within, coupled to, and extend out of themounting holes, 36206 ab, 36206 ac, 36206 ad, 36206 ae, 36206 af, 36206ag, 36206 ah, 36206 ai, and 36206 aj, respectively. In an exemplaryembodiment, the adjacent exterior arcuate cylindrical surfaces 36206 aaof the identical slip elements 36206 a of the upper tubular slipassembly 36206 together define a substantially contiguous cylindricalsurface.

A lower tubular slip assembly 36208 that receives and is movably mountedupon the tubular upper mandrel 3604 includes a plurality ofsubstantially identical slip elements 36208 a that each include anexterior arcuate cylindrical surface 36208 aa including mounting holes,36208 ab, 36208 ac, 36208 ad, 36208 ae, 36208 af, 36208 ag, 36208 ah,36208 ai, and 36208 aj, and grooves, 36208 aj and 36208 ak, a front endface 36208 a 1, a rear end face 36208 am including a mounting hole 36208an, side faces, 36208 ao and 36208 ap, an interior arcuate cylindricalsurface 36208 aq that mates with the exterior surface of the tubularupper mandrel 3604, and an interior tapered surface 36208 ar including amounting hole 36208 as. Mounting pins 36208 at are received within andcoupled to the mounting holes 36208 an and are received withincorresponding radial grooves 36204 b of the angled end face 36204 a ofthe lower tubular spacer ring 36204. Retaining pins 36208 au are mountedwithin and coupled to the mounting holes 36208 as that include heads36208 av. Slip retaining bands, 36208 aw and 36208 ax, are receivedwithin and coupled to grooves, 36208 aj and 36208 ak, respectively, ofthe slip elements 36208 a. Slip gripping elements, 36208 ay, 36208 az,36208 aaa, 36208 aab, 36208 aac, 36208 aad, 36208 aae, 36208 aaf, and36208 aag, are mounted within, coupled to, and extend out of themounting holes, 36208 ab, 36208 ac, 36208 ad, 36208 ae, 36208 af, 36208ag, 36208 ah, 36208 ai, and 36208 aj, respectively. In an exemplaryembodiment, the adjacent exterior arcuate cylindrical surfaces 36208 aaof the identical slip elements 36208 a of the upper tubular slipassembly 36208 together define a substantially contiguous cylindricalsurface.

An upper tubular wedge 36210 that receives the tubular upper mandrel3604 includes an angled front end face 36210 a including spaced apartradial grooves 36210 b, a rear end face 36210 c, an exterior cylindricalsurface 36210 d, a plurality of spaced apart faceted tapered exteriorsurface segments 36210 e that mate with corresponding tapered internalsurfaces 36206 ar of corresponding slip elements 36206 a of the uppertubular slip assembly 36206, and T-shaped exterior grooves 36210 faligned with the midline of corresponding faceted tapered exteriorsurface segments that extend from the angled end face to the rear endface that receive and mate with corresponding retaining pins 36206 au ofcorresponding slip elements of the upper tubular slip assembly. Theupper tubular wedge 36210 is releasably coupled to the tubular uppermandrel 3604 by shear pins 36211.

A lower tubular wedge 36212 that receives the tubular upper mandrel 3604includes an angled front end face 36212 a including spaced apart radialgrooves 36212 b, a rear end face 36212 c, an exterior cylindricalsurface 36212 d, a plurality of spaced apart faceted tapered exteriorsurface segments 36212 e that mate with corresponding tapered internalsurfaces 36208 ar of corresponding slip elements 36208 a of the uppertubular slip assembly 36208, and T-shaped exterior grooves 36212 faligned with the midline of corresponding faceted tapered exteriorsurface segments that extend from the angled end face to the rear endface that receive and mate with corresponding retaining pins 36208 au ofcorresponding slip elements of the lower tubular slip assembly. Thelower tubular wedge 36212 is releasably coupled to the tubular uppermandrel 3604 by shear pins 36213.

An upper tubular extrusion limiter assembly 36214 that receives and ismovably mounted upon the tubular upper mandrel 3604 includes a pluralityof substantially identical extrusion limiter elements 36214 a that eachinclude an angled front end face 36214 aa having a recessed portion36214 ab, an angled rear end face 36214 ac that defines a mounting hole36214 ad, an interior arcuate cylindrical surface 36214 ae that mateswith the tubular upper mandrel, and an exterior arcuate cylindricalsurface 36214 af including grooves, 36214 ag, 36214 ah, and 36214 ai.Disk extrusion preventers 36214 aj are mounted within and coupled to therecessed portions 36214 ab of adjacent extrusion limiter elements 36214a, and mounting pins 36214 ak are mounted within and coupled to mountingholes 36214 ad of corresponding extrusion limiter elements 36214 a thatare received within corresponding radial grooves 36210 b of the frontend face 36210 a of the upper tubular wedge 36210. Retaining bands,36214 a 1, 36214 am, and 36214 an, are positioned within and coupled tothe grooves, 36214 ai, 36214 ah, and 36214 ag, respectively, of theextrusion limiter elements 36214 a.

A lower tubular extrusion limiter assembly 36216 that receives and ismovably mounted upon the tubular upper mandrel 3604 includes a pluralityof substantially identical extrusion limiter elements 36216 a that eachinclude an angled front end face 36216 aa having a recessed portion36216 ab, an angled rear end face 36216 ac that defines a mounting hole36216 ad, an interior arcuate cylindrical surface 36216 ae that mateswith the tubular upper mandrel, and an exterior arcuate cylindricalsurface 36216 af including grooves, 36216 ag, 36216 ah, and 36216 ai.Disk extrusion preventers 36216 aj are mounted within and coupled to therecessed portions 36216 ab of adjacent extrusion limiter elements 36216a, and mounting pins 36216 ak are mounted within and coupled to mountingholes 36216 ad of corresponding extrusion limiter elements 36216 a thatare received within corresponding radial grooves 36212 b of the frontend face 36212 a of the lower tubular wedge 36212. Retaining bands,36216 a 1, 36216 am, and 36216 an, are positioned within and coupled tothe grooves, 36216 ag, 36216 ah, and 36216 ai, of the extrusion limiterelements 36216 a.

The angled end face 3640 b of the upper tubular elastomeric packerelement 3640 mates with and is positioned proximate the angled end faces36214 aa and disk extrusion preventers 36214 aj of the extrusion limiterelements 36214 a of the upper tubular extrusion limiter assembly 36214,and the angled end face 3642 b of the lower tubular elastomeric packerelement 3642 mates with and is positioned proximate the angled end faces36216 aa and disk extrusion preventers 36216 aj of the extrusion limiterelements 36216 a of the lower tubular extrusion limiter assembly 36216.

During operation of the alternative embodiment of the packer assembly 36described above with reference to FIGS. 21 and 21A to 21AX, the firststep in setting the packer assembly 36 includes pushing the slipelements, 36206 a and 36208 a, of the upper and lower slip assemblies,36206 and 36208, respectively, up the upper and lower tubular wedges,36210 and 36212, respectively, which breaks the retaining rings, 36206aw and 36206 ax, and 36208 aw and 36208 ax, respectively, and moves theslip elements outwardly against the interior surface of the expandablewellbore casing 100. In an exemplary embodiment, during the radialdisplacement of the slip elements, 36206 a and 36208 a, the retainingpins, 36206 au and 36208 au, respectively, and the mounting pins, 36206at and 36208 at, respectively, maintain the slip elements in an evenlyspaced apart configuration. In an exemplary embodiment, during theoperation of the packer assembly 36, the mounting pins, 36214 ak and36216 ak, maintain the extrusion limiter elements, 36214 a and 36216 a,of the upper and lower tubular extrusion limiter assemblies, 36214 and36216, respectively, in an evenly spaced apart configuration. Theoperation of the alternative embodiment of the packer assembly 36described above with reference to FIGS. 21 and 21A to 21AX is otherwisesubstantially identical to the operation of the packer assemblydescribed above with reference to FIGS. 20A1 to 20A5, 20B1 to 20B5, 20C1to 20C5, 20D1 to 20D5, 20E1 to 20E6, 20F1 to 20F6, 20G1 to 20G6, and20H1 to 20H5.

In an exemplary embodiment, the system 10 is provided as illustrated inAppendix A to the present application which corresponds generally to theextension actuator assembly 26 described above with reference to FIGS.15-1, 15-2, 15A1, 15A2, 15B1, 15B2, 15C1, 15C2, 15D, 15E1 to 15E5, 15F1to 15F5, and 15G1 to 15G5.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember, a cutting device for cutting the tubular member coupled to thesupport member, and an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member.In an exemplary embodiment, the apparatus further includes a grippingdevice for gripping the tubular member coupled to the support member. Inan exemplary embodiment, the gripping device comprises a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and, if the tubular member is displacedin a second axial direction, the gripping device does not grip thetubular member. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes: a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the apparatusfurther includes an actuator for displacing the expansion devicerelative to the support member. In an exemplary embodiment, the actuatorincludes a first actuator for pulling the expansion device; and a secondactuator for pushing the expansion device. In an exemplary embodiment,the actuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements includes a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember, an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member, and anactuator coupled to the support member for displacing the expansiondevice relative to the support member. In an exemplary embodiment, theapparatus further includes a cutting device coupled to the supportmember for cutting the tubular member. In an exemplary embodiment, thecutting device includes a support member; and a plurality of movablecutting elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the cutting elements between a first positionand a second position; wherein in the first position, the cuttingelements do not engage the tubular member; and wherein in the secondposition, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theapparatus further includes a gripping device for gripping the tubularmember coupled to the support member. In an exemplary embodiment, thegripping device includes a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, if the tubular member isdisplaced in a first axial direction, the gripping device grips thetubular member; and wherein, if the tubular member is displaced in asecond axial direction, the gripping device does not grip the tubularmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member, and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device comprises: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the expansiondevice includes a support member; and a plurality of movable expansionelements coupled to the support member. In an exemplary embodiment, theapparatus further includes an actuator coupled to the support member formoving the expansion elements between a first position and a secondposition; wherein in the first position, the expansion elements do notengage the tubular member; and wherein in the second position, theexpansion elements engage the tubular member. In an exemplaryembodiment, the apparatus further includes a sensor coupled to thesupport member for sensing the internal diameter of the tubular member.In an exemplary embodiment, the sensor prevents the expansion elementsfrom being moved to the second position if the internal diameter of thetubular member is less than a predetermined value. In an exemplaryembodiment, the expansion elements include a first set of expansionelements; and a second set of expansion elements; wherein the first setof expansion elements are interleaved with the second set of expansionelements. In an exemplary embodiment, the in the first position, thefirst set of expansion elements are not axially aligned with the secondset of expansion elements. In an exemplary embodiment, in the secondposition, the first set of expansion elements are axially aligned withthe second set of expansion elements. In an exemplary embodiment, theexpansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and asealing assembly for sealing an annulus defined between the supportmember and the tubular member. In an exemplary embodiment, the apparatusfurther includes a gripping device for gripping the tubular membercoupled to the support member. In an exemplary embodiment, the grippingdevice includes a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, the if the tubularmember is displaced in a first axial direction, the gripping devicegrips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes a supportmember; one or more drag blocks releasably coupled to the supportmember; and a stinger coupled to the support member for engaging thesliding sleeve valve. In an exemplary embodiment, the apparatus furtherincludes an actuator for displacing the expansion device relative to thesupport member. In an exemplary embodiment, the actuator includes afirst actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device. In an exemplary embodiment, theactuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators comprise means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements includes a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; a first expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and a secondexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member. In an exemplaryembodiment, the apparatus further includes a gripping device forgripping the tubular member coupled to the support member. In anexemplary embodiment, the gripping device includes a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device comprises: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the apparatusfurther includes an actuator for displacing the expansion devicerelative to the support member. In an exemplary embodiment, the actuatorincludes a first actuator for pulling the expansion device; and a secondactuator for pushing the expansion device. In an exemplary embodiment,the actuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the apparatus further includes a cutting device for cuttingthe tubular member coupled to the support member. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, at least oneof the first second expansion devices include a support member; and aplurality of movable expansion elements coupled to the support member.In an exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the expansion elements betweena first position and a second position; wherein in the first position,the expansion elements do not engage the tubular member; and wherein inthe second position, the expansion elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theexpansion elements from being moved to the second position if theinternal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the expansion elements include afirst set of expansion elements; and a second set of expansion elements;wherein the first set of expansion elements are interleaved with thesecond set of expansion elements. In an exemplary embodiment, in thefirst position, the first set of expansion elements are not axiallyaligned with the second set of expansion elements. In an exemplaryembodiment, in the second position, the first set of expansion elementsare axially aligned with the second set of expansion elements. In anexemplary embodiment, at least one of the first and second expansiondevices comprise a plurality of expansion devices. In an exemplaryembodiment, at least one of the first and second expansion devicecomprise an adjustable expansion device. In an exemplary embodiment, theadjustable expansion device includes a support member; and a pluralityof movable expansion elements coupled to the support member. In anexemplary embodiment, the apparatus further includes an actuator coupledto the support member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and a packercoupled to the support member. In an exemplary embodiment, the apparatusfurther includes a gripping device for gripping the tubular membercoupled to the support member. In an exemplary embodiment, the grippingdevice comprises a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, if the tubular member isdisplaced in a first axial direction, the gripping device grips thetubular member; and wherein, if the tubular member is displaced in asecond axial direction, the gripping device does not grip the tubularmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the packer assembly includes a packer; and apacker control device for controlling the operation of the packercoupled to the support member. In an exemplary embodiment, the packerincludes a support member defining a passage; a shoe comprising a floatvalve coupled to an end of the support member; one or more compressiblepacker elements movably coupled to the support member; and a slidingsleeve valve movably positioned within the passage of the supportmember. In an exemplary embodiment, the packer control device includes asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe packer. In an exemplary embodiment, the packer includes a supportmember defining a passage; a shoe comprising a float valve coupled to anend of the support member; one or more compressible packer elementsmovably coupled to the support member; and a sliding sleeve valvepositioned within the passage of the support member; and wherein thepacker control device includes a support member; one or more drag blocksreleasably coupled to the support member; and a stinger coupled to thesupport member for engaging the sliding sleeve valve. In an exemplaryembodiment, the apparatus further includes an actuator for displacingthe expansion device relative to the support member. In an exemplaryembodiment, the actuator includes a first actuator for pulling theexpansion device; and a second actuator for pushing the expansiondevice. In an exemplary embodiment, the actuator includes means fortransferring torsional loads between the support member and theexpansion device. In an exemplary embodiment, the first and secondactuators include means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, theactuator includes a plurality of pistons positioned within correspondingpiston chambers. In an exemplary embodiment, the apparatus furtherincludes a cutting device coupled to the support member for cutting thetubular member. In an exemplary embodiment, the cutting device includesa support member; and a plurality of movable cutting elements coupled tothe support member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving thecutting elements between a first position and a second position; whereinin the first position, the cutting elements do not engage the tubularmember; and wherein in the second position, the cutting elements engagethe tubular member. In an exemplary embodiment, the apparatus furtherincludes a sensor coupled to the support member for sensing the internaldiameter of the tubular member. In an exemplary embodiment, the sensorprevents the cutting elements from being moved to the second position ifthe internal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the cutting elements include a firstset of cutting elements; and a second set of cutting elements; whereinthe first set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices comprises an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; a cutting device for cutting the tubular member coupled to thesupport member; a gripping device for gripping the tubular membercoupled to the support member; a sealing device for sealing an interfacewith the tubular member coupled to the support member; a locking devicefor locking the position of the tubular member relative to the supportmember; a first adjustable expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;a second adjustable expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;a packer coupled to the support member; and an actuator for displacingone or more of the sealing assembly, first and second adjustableexpansion devices, and packer relative to the support member. In anexemplary embodiment, the gripping device includes a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the sealing device seals an annulus defines between thesupport member and the tubular member. In an exemplary embodiment, thepacker assembly includes a packer; and a packer control device forcontrolling the operation of the packer coupled to the support member.In an exemplary embodiment, the packer includes a support memberdefining a passage; a shoe comprising a float valve coupled to an end ofthe support member; one or more compressible packer elements movablycoupled to the support member; and a sliding sleeve valve movablypositioned within the passage of the support member. In an exemplaryembodiment, the packer control device includes a support member; one ormore drag blocks releasably coupled to the support member; and a stingercoupled to the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes a supportmember; one or more drag blocks releasably coupled to the supportmember; and a stinger coupled to the support member for engaging thesliding sleeve valve. In an exemplary embodiment, the actuator includesa first actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device. In an exemplary embodiment, theactuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, at least oneof the adjustable expansion devices include a support member; and aplurality of movable expansion elements coupled to the support member.In an exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the expansion elements betweena first position and a second position; wherein in the first position,the expansion elements do not engage the tubular member; and wherein inthe second position, the expansion elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theexpansion elements from being moved to the second position if theinternal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the expansion elements include afirst set of expansion elements; and a second set of expansion elements;wherein the first set of expansion elements are interleaved with thesecond set of expansion elements. In an exemplary embodiment, in thefirst position, the first set of expansion elements are not axiallyaligned with the second set of expansion elements. In an exemplaryembodiment, in the second position, the first set of expansion elementsare axially aligned with the second set of expansion elements. In anexemplary embodiment, at least one of the adjustable expansion devicescomprise a plurality of expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices include a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for cutting a tubular member has been described thatincludes a support member; and a plurality of movable cutting elementscoupled to the support member. In an exemplary embodiment, the apparatusfurther includes an actuator coupled to the support member for movingthe cutting elements between a first position and a second position;wherein in the first position, the cutting elements do not engage thetubular member; and wherein in the second position, the cutting elementsengage the tubular member. In an exemplary embodiment, the apparatusfurther includes a sensor coupled to the support member for sensing theinternal diameter of the tubular member. In an exemplary embodiment, thesensor prevents the cutting elements from being moved to the secondposition if the internal diameter of the tubular member is less than apredetermined value. In an exemplary embodiment, the cutting elementsinclude a first set of cutting elements; and a second set of cuttingelements; wherein the first set of cutting elements are interleaved withthe second set of cutting elements. In an exemplary embodiment, in thefirst position, the first set of cutting elements are not axiallyaligned with the second set of cutting elements. In an exemplaryembodiment, in the second position, the first set of cutting elementsare axially aligned with the second set of cutting elements.

An apparatus for engaging a tubular member has been described thatincludes a support member; and a plurality of movable elements coupledto the support member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theelements between a first position and a second position; wherein in thefirst position, the elements do not engage the tubular member; andwherein in the second position, the elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the elements include a first set of elements; anda second set of elements; wherein the first set of elements areinterleaved with the second set of elements. In an exemplary embodiment,in the first position, the first set of elements are not axially alignedwith the second set of elements. In an exemplary embodiment, in thesecond position, the first set of elements are axially aligned with thesecond set of elements.

An apparatus for gripping a tubular member has been described thatincludes a plurality of movable gripping elements. In an exemplaryembodiment, the gripping elements are moveable in a radial direction. Inan exemplary embodiment, the gripping elements are moveable in an axialdirection. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radialdirection. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axialdirection. In an exemplary embodiment, in a first axial direction, thegripping device grips the tubular member; and wherein, in a second axialdirection, the gripping device does not grip the tubular member. In anexemplary embodiment, the apparatus further includes an actuator formoving the gripping elements. In an exemplary embodiment, the grippingelements include a plurality of separate and distinct gripping elements.

An actuator has been described that includes a tubular housing; atubular piston rod movably coupled to and at least partially positionedwithin the housing; a plurality of annular piston chambers defined bythe tubular housing and the tubular piston rod; and a plurality oftubular pistons coupled to the tubular piston rod, each tubular pistonmovably positioned within a corresponding annular piston chamber. In anexemplary embodiment, the actuator further includes means fortransmitting torsional loads between the tubular housing and the tubularpiston rod.

An apparatus for controlling a packer has been described that includes atubular support member; one or more drag blocks releasably coupled tothe tubular support member; and a tubular stinger coupled to the tubularsupport member for engaging the packer. In an exemplary embodiment, theapparatus further includes a tubular sleeve coupled to the drag blocks.In an exemplary embodiment, the tubular support member includes one ormore axially aligned teeth for engaging the packer.

A packer has been described that includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member.

A method of radially expanding and plastically deforming an expandabletubular member within a borehole having a preexisting wellbore casinghas been described that includes positioning the tubular member withinthe borehole in overlapping relation to the wellbore casing; radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section; and radially expanding and plastically deforming aportion of the tubular member above the bell section comprising aportion of the tubular member that overlaps with the wellbore casing;wherein the inside diameter of the bell section is greater than theinside diameter of the radially expanded and plastically deformedportion of the tubular member above the bell section. In an exemplaryembodiment, radially expanding and plastically deforming a portion ofthe tubular member to form a bell section includes positioning anadjustable expansion device within the expandable tubular member;supporting the expandable tubular member and the adjustable expansiondevice within the borehole; lowering the adjustable expansion device outof the expandable tubular member; increasing the outside dimension ofthe adjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member n times toradially expand and plastically deform n portions of the expandabletubular member, wherein n is greater than or equal to 1.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning an adjustable expansion device within a firstexpandable tubular member; supporting the first expandable tubularmember and the adjustable expansion device within a borehole; loweringthe adjustable expansion device out of the first expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; displacing the adjustable expansion device upwardly relative tothe first expandable tubular member m times to radially expand andplastically deform m portions of the first expandable tubular memberwithin the borehole; positioning the adjustable expansion device withina second expandable tubular member; supporting the second expandabletubular member and the adjustable expansion device within the boreholein overlapping relation to the first expandable tubular member; loweringthe adjustable expansion device out of the second expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; and displacing the adjustable expansion device upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning an adjustable expansion device within the expandable tubularmember; supporting the expandable tubular member and the adjustableexpansion device within the borehole; lowering the adjustable expansiondevice out of the expandable tubular member; increasing the outsidedimension of the adjustable expansion device; displacing the adjustableexpansion mandrel upwardly relative to the expandable tubular member ntimes to radially expand and plastically deform n portions of theexpandable tubular member within the borehole; and pressurizing aninterior region of the expandable tubular member above the adjustableexpansion device during the radial expansion and plastic deformation ofthe expandable tubular member within the borehole.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning an adjustable expansion device within a firstexpandable tubular member; supporting the first expandable tubularmember and the adjustable expansion device within a borehole; loweringthe adjustable expansion device out of the first expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; displacing the adjustable expansion device upwardly relative tothe first expandable tubular member m times to radially expand andplastically deform m portions of the first expandable tubular memberwithin the borehole; pressurizing an interior region of the firstexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the first expandabletubular member within the borehole; positioning the adjustable expansionmandrel within a second expandable tubular member; supporting the secondexpandable tubular member and the adjustable expansion mandrel withinthe borehole in overlapping relation to the first expandable tubularmember; lowering the adjustable expansion mandrel out of the secondexpandable tubular member; increasing the outside dimension of theadjustable expansion mandrel; displacing the adjustable expansionmandrel upwardly relative to the second expandable tubular member ntimes to radially expand and plastically deform n portions of the secondexpandable tubular member within the borehole; and pressurizing aninterior region of the second expandable tubular member above theadjustable expansion mandrel during the radial expansion and plasticdeformation of the second expandable tubular member within the borehole.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning first and second adjustable expansion devices within theexpandable tubular member; supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;lowering the first adjustable expansion device out of the expandabletubular member; increasing the outside dimension of the first adjustableexpansion device; displacing the first adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform a lower portion of the expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning first and second adjustable expansion deviceswithin a first expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; lowering the first adjustable expansiondevice out of the first expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deform alower portion of the first expandable tubular member; displacing thefirst adjustable expansion device and the second adjustable expansiondevice downwardly relative to the first expandable tubular member;decreasing the outside dimension of the first adjustable expansiondevice and increasing the outside dimension of the second adjustableexpansion device; displacing the second adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform portions of the first expandable tubularmember above the lower portion of the expandable tubular member;positioning first and second adjustable expansion devices within asecond expandable tubular member; supporting the first expandabletubular member and the first and second adjustable expansion deviceswithin the borehole in overlapping relation to the first expandabletubular member; lowering the first adjustable expansion device out ofthe second expandable tubular member; increasing the outside dimensionof the first adjustable expansion device; displacing the firstadjustable expansion device upwardly relative to the second expandabletubular member to radially expand and plastically deform a lower portionof the second expandable tubular member; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the second expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; anddisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning first and second adjustable expansion devices within theexpandable tubular member; supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;lowering the first adjustable expansion device out of the expandabletubular member; increasing the outside dimension of the first adjustableexpansion device; displacing the first adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform a lower portion of the expandable tubular member;pressurizing an interior region of the expandable tubular member abovethe first adjustable expansion device during the radial expansion of thelower portion of the expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to theexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the expandable tubular member toradially expand and plastically deform portions of the expandabletubular member above the lower portion of the expandable tubular member;and pressurizing an interior region of the expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the expandable tubular member above the lower portionof the expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning first and second adjustable expansion deviceswithin a first expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; lowering the first adjustable expansiondevice out of the first expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deform alower portion of the first expandable tubular member; pressurizing aninterior region of the first expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the first expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform portions of the firstexpandable tubular member above the lower portion of the expandabletubular member; pressurizing an interior region of the first expandabletubular member above the second adjustable expansion device during theradial expansion of the portions of the first expandable tubular memberabove the lower portion of the first expandable tubular member by thesecond adjustable expansion device; positioning first and secondadjustable expansion devices within a second expandable tubular member;supporting the first expandable tubular member and the first and secondadjustable expansion devices within the borehole in overlapping relationto the first expandable tubular member; lowering the first adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the first adjustable expansion device;displacing the first adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform a lower portion of the second expandable tubular member;pressurizing an interior region of the second expandable tubular memberabove the first adjustable expansion device during the radial expansionof the lower portion of the second expandable tubular member by thefirst adjustable expansion device; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the second expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; displacingthe second adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deformportions of the second expandable tubular member above the lower portionof the second expandable tubular member; and pressurizing an interiorregion of the second expandable tubular member above the secondadjustable expansion device during the radial expansion of the portionsof the second expandable tubular member above the lower portion of thesecond expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includessupporting the expandable tubular member, an hydraulic actuator, and anadjustable expansion device within the borehole; increasing the size ofthe adjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform a portionof the expandable tubular member. In an exemplary embodiment, the methodfurther includes reducing the size of the adjustable expansion deviceafter the portion of the expandable tubular member has been radiallyexpanded and plastically deformed. In an exemplary embodiment, themethod further includes fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the method further includes permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the method further includes injecting a hardenable fluidicsealing material into an annulus between the expandable tubular memberand a preexisting structure after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the method furtherincludes increasing the size of the adjustable expansion device afterpermitting the position of the expandable tubular member to floatrelative to the position of the hydraulic actuator. In an exemplaryembodiment, the method further includes displacing the adjustableexpansion cone upwardly relative to the expandable tubular member toradially expand and plastically deform another portion of the expandabletubular member. In an exemplary embodiment, the method further includesif the end of the other portion of the expandable tubular memberoverlaps with a preexisting structure, then not permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator; and displacing the adjustable expansion coneupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform the end of the otherportion of the expandable tubular member that overlaps with thepreexisting structure.

A method for forming a mono diameter wellbore casing within a boreholethat includes a preexisting wellbore casing has been described thatincludes supporting the expandable tubular member, an hydraulicactuator, and an adjustable expansion device within the borehole;increasing the size of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the expandable tubularmember using the hydraulic actuator to radially expand and plasticallydeform a portion of the expandable tubular member; and displacing theadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform the remaining portionof the expandable tubular member and a portion of the preexistingwellbore casing that overlaps with an end of the remaining portion ofthe expandable tubular member. In an exemplary embodiment, the methodfurther includes reducing the size of the adjustable expansion deviceafter the portion of the expandable tubular member has been radiallyexpanded and plastically deformed. In an exemplary embodiment, themethod further includes fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the method further includes permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the method further includes injecting a hardenable fluidicsealing material into an annulus between the expandable tubular memberand the borehole after permitting the position of the expandable tubularmember to float relative to the position of the hydraulic actuator. Inan exemplary embodiment, the method further includes increasing the sizeof the adjustable expansion device after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the method furtherincludes displacing the adjustable expansion cone upwardly relative tothe expandable tubular member to radially expand and plastically deformthe remaining portion of the expandable tubular member. In an exemplaryembodiment, the method further includes not permitting the position ofthe expandable tubular member to float relative to the position of thehydraulic actuator; and displacing the adjustable expansion coneupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform the end of theremaining portion of the expandable tubular member that overlaps withthe preexisting wellbore casing after not permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator.

A method of radially expanding and plastically deforming a tubularmember has been described that includes positioning the tubular memberwithin a preexisting structure; radially expanding and plasticallydeforming a lower portion of the tubular member to form a bell section;and radially expanding and plastically deforming a portion of thetubular member above the bell section. In an exemplary embodiment,positioning the tubular member within a preexisting structure includeslocking the tubular member to an expansion device. In an exemplaryembodiment, the outside diameter of the expansion device is less thanthe inside diameter of the tubular member. In an exemplary embodiment,the expansion device is positioned within the tubular member. In anexemplary embodiment, the expansion device includes an adjustableexpansion device. In an exemplary embodiment, the adjustable expansiondevice is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of expansiondevices. In an exemplary embodiment, at least one of the expansiondevices includes an adjustable expansion device. In an exemplaryembodiment, at least one of the adjustable expansion device isadjustable to a plurality of sizes. In an exemplary embodiment, radiallyexpanding and plastically deforming a lower portion of the tubularmember to form a bell section includes lowering an expansion device outof an end of the tubular member; and pulling the expansion devicethrough the end of the tubular member. In an exemplary embodiment,lowering an expansion device out of an end of the tubular memberincludes lowering the expansion device out of the end of the tubularmember; and adjusting the size of the expansion device. In an exemplaryembodiment, the adjustable expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device includes aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes gripping thetubular member; and pulling an expansion device through an end of thetubular member. In an exemplary embodiment, gripping the tubular memberincludes permitting axial displacement of the tubular member in a firstdirection; and not permitting axial displacement of the tubular memberin a second direction. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes pulling theexpansion device through the end of the tubular member using anactuator. In an exemplary embodiment, radially expanding and plasticallydeforming a portion of the tubular member above the bell sectionincludes lowering an expansion device out of an end of the tubularmember; and pulling the expansion device through the end of the tubularmember. In an exemplary embodiment, lowering an expansion device out ofan end of the tubular member includes lowering the expansion device outof the end of the tubular member; and adjusting the size of theexpansion device. In an exemplary embodiment, the adjustable expansiondevice is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of adjustableexpansion devices. In an exemplary embodiment, at least one of theadjustable expansion devices is adjustable to a plurality of sizes. Inan exemplary embodiment, pulling the expansion device through the end ofthe tubular member includes gripping the tubular member; and pulling anexpansion device through an end of the tubular member. In an exemplaryembodiment, gripping the tubular member includes permitting axialdisplacement of the tubular member in a first direction; and notpermitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, pulling the expansion devicethrough the end of the tubular member includes pulling the expansiondevice through the end of the tubular member using an actuator. In anexemplary embodiment, pulling the expansion device through the end ofthe tubular member includes pulling the expansion device through the endof the tubular member using fluid pressure. In an exemplary embodiment,pulling the expansion device through the end of the tubular member usingfluid pressure includes pressurizing an annulus within the tubularmember above the expansion device. In an exemplary embodiment, radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section includes fluidicly sealing an end of the tubularmember; and pulling the expansion device through the tubular member. Inan exemplary embodiment, the expansion device is adjustable. In anexemplary embodiment, the expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device comprises aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes gripping thetubular member; and pulling an expansion device through an end of thetubular member. In an exemplary embodiment, gripping the tubular memberincludes permitting axial displacement of the tubular member in a firstdirection; and not permitting axial displacement of the tubular memberin a second direction. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes pulling theexpansion device through the end of the tubular member using anactuator. In an exemplary embodiment, pulling the expansion devicethrough the end of the tubular member includes pulling the expansiondevice through the end of the tubular member using fluid pressure. In anexemplary embodiment, pulling the expansion device through the end ofthe tubular member using fluid pressure includes pressurizing an annuluswithin the tubular member above the expansion device. In an exemplaryembodiment, radially expanding and plastically deforming a portion ofthe tubular member above the bell section includes overlapping theportion of the tubular member above the bell section with an end of apreexisting tubular member; and pulling an expansion device through theoverlapping portions of the tubular member and the preexisting tubularmember. In an exemplary embodiment, the expansion device is adjustable.In an exemplary embodiment, the expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of adjustable expansion devices. In an exemplaryembodiment, at least one of the adjustable expansion devices isadjustable to a plurality of sizes. In an exemplary embodiment, pullingthe expansion device through the overlapping portions of the tubularmember and the preexisting tubular member includes gripping the tubularmember; and pulling the expansion device through the overlappingportions of the tubular member and the preexisting tubular member. In anexemplary embodiment, gripping the tubular member includes permittingaxial displacement of the tubular member in a first direction; and notpermitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, pulling the expansion devicethrough the overlapping portions of the tubular member and thepreexisting tubular member includes pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member using an actuator. In an exemplary embodiment, pullingthe expansion device through the overlapping portions of the tubularmember and the preexisting tubular member includes pulling the expansiondevice through the overlapping portions of the tubular member and thepreexisting tubular member using fluid pressure. In an exemplaryembodiment, pulling the expansion device through the overlappingportions of the tubular member and the preexisting tubular member usingfluid pressure includes pressurizing an annulus within the tubularmember above the expansion device. In an exemplary embodiment, themethod further includes cutting an end of the portion of the tubularmember that overlaps with the preexisting tubular member. In anexemplary embodiment, the method further includes removing the cut offend of the expandable tubular member from the preexisting structure. Inan exemplary embodiment, the method further includes injecting ahardenable fluidic sealing material into an annulus between theexpandable tubular member and the preexisting structure. In an exemplaryembodiment, the method further includes cutting off an end of theexpandable tubular member. In an exemplary embodiment, the methodfurther includes removing the cut off end of the expandable tubularmember from the preexisting structure.

A method of radially expanding and plastically deforming a tubularmember has been described that includes applying internal pressure tothe inside surface of the tubular member at a plurality of discretelocation separated from one another.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole having a preexisting wellbore casinghas been described that includes means for positioning the tubularmember within the borehole in overlapping relation to the wellborecasing; means for radially expanding and plastically deforming a portionof the tubular member to form a bell section; and means for radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section comprising a portion of the tubular member thatoverlaps with the wellbore casing; wherein the inside diameter of thebell section is greater than the inside diameter of the radiallyexpanded and plastically deformed portion of the tubular member abovethe bell section. In an exemplary embodiment, means for radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section includes means for positioning an adjustableexpansion device within the expandable tubular member; means forsupporting the expandable tubular member and the adjustable expansiondevice within the borehole; means for lowering the adjustable expansiondevice out of the expandable tubular member; means for increasing theoutside dimension of the adjustable expansion device; and means fordisplacing the adjustable expansion device upwardly relative to theexpandable tubular member n times to radially expand and plasticallydeform n portions of the expandable tubular member, wherein n is greaterthan or equal to 1.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning an adjustable expansion devicewithin a first expandable tubular member; means for supporting the firstexpandable tubular member and the adjustable expansion device within aborehole; means for lowering the adjustable expansion device out of thefirst expandable tubular member; means for increasing the outsidedimension of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;means for positioning the adjustable expansion device within a secondexpandable tubular member; means for supporting the second expandabletubular member and the adjustable expansion device within the boreholein overlapping relation to the first expandable tubular member; meansfor lowering the adjustable expansion device out of the secondexpandable tubular member; means for increasing the outside dimension ofthe adjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the second expandable tubularmember n times to radially expand and plastically deform n portions ofthe second expandable tubular member within the borehole.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning an adjustable expansion device within the expandabletubular member; means for supporting the expandable tubular member andthe adjustable expansion device within the borehole; means for loweringthe adjustable expansion device out of the expandable tubular member;means for increasing the outside dimension of the adjustable expansiondevice; means for displacing the adjustable expansion mandrel upwardlyrelative to the expandable tubular member n times to radially expand andplastically deform n portions of the expandable tubular member withinthe borehole; and means for pressurizing an interior region of theexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the expandable tubularmember within the borehole.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning an adjustable expansion devicewithin a first expandable tubular member; means for supporting the firstexpandable tubular member and the adjustable expansion device within aborehole; means for lowering the adjustable expansion device out of thefirst expandable tubular member; means for increasing the outsidedimension of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;means for pressurizing an interior region of the first expandabletubular member above the adjustable expansion device during the radialexpansion and plastic deformation of the first expandable tubular memberwithin the borehole; means for positioning the adjustable expansionmandrel within a second expandable tubular member; means for supportingthe second expandable tubular member and the adjustable expansionmandrel within the borehole in overlapping relation to the firstexpandable tubular member; means for lowering the adjustable expansionmandrel out of the second expandable tubular member; means forincreasing the outside dimension of the adjustable expansion mandrel;means for displacing the adjustable expansion mandrel upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole; and means for pressurizing an interior region ofthe second expandable tubular member above the adjustable expansionmandrel during the radial expansion and plastic deformation of thesecond expandable tubular member within the borehole.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning first and second adjustable expansion devices within theexpandable tubular member; means for supporting the expandable tubularmember and the first and second adjustable expansion devices within theborehole; means for lowering the first adjustable expansion device outof the expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe first adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform alower portion of the expandable tubular member; means for displacing thefirst adjustable expansion device and the second adjustable expansiondevice downwardly relative to the expandable tubular member; means fordecreasing the outside dimension of the first adjustable expansiondevice and increasing the outside dimension of the second adjustableexpansion device; means for displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning first and second adjustableexpansion devices within a first expandable tubular member; means forsupporting the first expandable tubular member and the first and secondadjustable expansion devices within a borehole; means for lowering thefirst adjustable expansion device out of the first expandable tubularmember; means for increasing the outside dimension of the firstadjustable expansion device; displacing the first adjustable expansiondevice upwardly relative to the first expandable tubular member toradially expand and plastically deform a lower portion of the firstexpandable tubular member; means for displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the first expandable tubular member; means for decreasingthe outside dimension of the first adjustable expansion device andincreasing the outside dimension of the second adjustable expansiondevice; means for displacing the second adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform portions of the first expandable tubularmember above the lower portion of the expandable tubular member; meansfor positioning first and second adjustable expansion devices within asecond expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within the borehole in overlapping relation to the firstexpandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the adjustable expansion device upwardlyrelative to the second expandable tubular member to radially expand andplastically deform a lower portion of the second expandable tubularmember; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; and means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning first and second adjustable expansion devices within theexpandable tubular member; means for supporting the expandable tubularmember and the first and second adjustable expansion devices within theborehole; means for lowering the first adjustable expansion device outof the expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe first adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform alower portion of the expandable tubular member; means for pressurizingan interior region of the expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the expandable tubular member by the first adjustableexpansion device; means for displacing the first adjustable expansiondevice and the second adjustable expansion device downwardly relative tothe expandable tubular member; means for decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe expandable tubular member to radially expand and plastically deformportions of the expandable tubular member above the lower portion of theexpandable tubular member; and means for pressurizing an interior regionof the expandable tubular member above the second adjustable expansiondevice during the radial expansion of the portions of the expandabletubular member above the lower portion of the expandable tubular memberby the second adjustable expansion device; wherein the outside dimensionof the first adjustable expansion device is greater than the outsidedimension of the second adjustable expansion device.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning first and second adjustableexpansion devices within a first expandable tubular member; means forsupporting the first expandable tubular member and the first and secondadjustable expansion devices within a borehole; means for lowering thefirst adjustable expansion device out of the first expandable tubularmember; means for increasing the outside dimension of the firstadjustable expansion device; means for displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; means for pressurizing an interiorregion of the first expandable tubular member above the first adjustableexpansion device during the radial expansion of the lower portion of thefirst expandable tubular member by the first adjustable expansiondevice; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe first expandable tubular member to radially expand and plasticallydeform portions of the first expandable tubular member above the lowerportion of the expandable tubular member; means for pressurizing aninterior region of the first expandable tubular member above the secondadjustable expansion device during the radial expansion of the portionsof the first expandable tubular member above the lower portion of thefirst expandable tubular member by the second adjustable expansiondevice; means for positioning first and second adjustable expansiondevices within a second expandable tubular member; means for supportingthe first expandable tubular member and the first and second adjustableexpansion devices within the borehole in overlapping relation to thefirst expandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the second expandable tubular member to radiallyexpand and plastically deform a lower portion of the second expandabletubular member; means for pressurizing an interior region of the secondexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the secondexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; and means forpressurizing an interior region of the second expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the second expandable tubular member above the lowerportion of the second expandable tubular member by the second adjustableexpansion device; wherein the outside dimension of the first adjustableexpansion device is greater than the outside dimension of the secondadjustable expansion device.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor supporting the expandable tubular member, an hydraulic actuator, andan adjustable expansion device within the borehole; means for increasingthe size of the adjustable expansion device; and means for displacingthe adjustable expansion device upwardly relative to the expandabletubular member using the hydraulic actuator to radially expand andplastically deform a portion of the expandable tubular member. In anexemplary embodiment, the system further includes means for reducing thesize of the adjustable expansion device after the portion of theexpandable tubular member has been radially expanded and plasticallydeformed. In an exemplary embodiment, the system further includes meansfor fluidicly sealing the radially expanded and plastically deformed endof the expandable tubular member after reducing the size of theadjustable expansion device. In an exemplary embodiment, the systemfurther includes means for permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the system further includes means for injecting a hardenablefluidic sealing material into an annulus between the expandable tubularmember and a preexisting structure after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the system furtherincludes means for increasing the size of the adjustable expansiondevice after permitting the position of the expandable tubular member tofloat relative to the position of the hydraulic actuator. In anexemplary embodiment, system further includes means for displacing theadjustable expansion cone upwardly relative to the expandable tubularmember to radially expand and plastically deform another portion of theexpandable tubular member. In an exemplary embodiment, the systemfurther includes if the end of the other portion of the expandabletubular member overlaps with a preexisting structure, then means for notpermitting the position of the expandable tubular member to floatrelative to the position of the hydraulic actuator; and means fordisplacing the adjustable expansion cone upwardly relative to theexpandable tubular member using the hydraulic actuator to radiallyexpand and plastically deform the end of the other portion of theexpandable tubular member that overlaps with the preexisting structure.

A system for forming a mono diameter wellbore casing within a boreholethat includes a preexisting wellbore casing has been described thatincludes means for supporting the expandable tubular member, anhydraulic actuator, and an adjustable expansion device within theborehole; means for increasing the size of the adjustable expansiondevice; means for displacing the adjustable expansion device upwardlyrelative to the expandable tubular member using the hydraulic actuatorto radially expand and plastically deform a portion of the expandabletubular member; and means for displacing the adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform the remaining portion of the expandable tubularmember and a portion of the preexisting wellbore casing that overlapswith an end of the remaining portion of the expandable tubular member.In an exemplary embodiment, the system further includes means forreducing the size of the adjustable expansion device after the portionof the expandable tubular member has been radially expanded andplastically deformed. In an exemplary embodiment, the system furtherincludes means for fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the system further includes means for permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator after fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member. In anexemplary embodiment, the system further includes means for injecting ahardenable fluidic sealing material into an annulus between theexpandable tubular member and the borehole after permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator. In an exemplary embodiment, the system furtherincludes means for increasing the size of the adjustable expansiondevice after permitting the position of the expandable tubular member tofloat relative to the position of the hydraulic actuator. In anexemplary embodiment, the system further includes means for displacingthe adjustable expansion cone upwardly relative to the expandabletubular member to radially expand and plastically deform the remainingportion of the expandable tubular member. In an exemplary embodiment,the system further includes means for not permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator; and means for displacing the adjustable expansioncone upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform the end ofthe remaining portion of the expandable tubular member that overlapswith the preexisting wellbore casing after not permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning thetubular member within a preexisting structure; means for radiallyexpanding and plastically deforming a lower portion of the tubularmember to form a bell section; and means for radially expanding andplastically deforming a portion of the tubular member above the bellsection. In an exemplary embodiment, positioning the tubular memberwithin a preexisting structure includes means for locking the tubularmember to an expansion device. In an exemplary embodiment, the outsidediameter of the expansion device is less than the inside diameter of thetubular member. In an exemplary embodiment, the expansion device ispositioned within the tubular member. In an exemplary embodiment, theexpansion device includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of expansion devices. In an exemplary embodiment,at least one of the expansion devices includes an adjustable expansiondevice. In an exemplary embodiment, at least one of the adjustableexpansion device is adjustable to a plurality of sizes. In an exemplaryembodiment, means for radially expanding and plastically deforming alower portion of the tubular member to form a bell section includesmeans for lowering an expansion device out of an end of the tubularmember; and means for pulling the expansion device through the end ofthe tubular member. In an exemplary embodiment, means for lowering anexpansion device out of an end of the tubular member includes means forlowering the expansion device out of the end of the tubular member; andmeans for adjusting the size of the expansion device. In an exemplaryembodiment, the adjustable expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device includes aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, means for pulling theexpansion device through the end of the tubular member includes meansfor gripping the tubular member; and means for pulling an expansiondevice through an end of the tubular member. In an exemplary embodiment,means for gripping the tubular member includes means for permittingaxial displacement of the tubular member in a first direction; and meansfor not permitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, means for pulling the expansiondevice through the end of the tubular member includes means for pullingthe expansion device through the end of the tubular member using anactuator. In an exemplary embodiment, means for radially expanding andplastically deforming a portion of the tubular member above the bellsection includes means for lowering an expansion device out of an end ofthe tubular member; and means for pulling the expansion device throughthe end of the tubular member. In an exemplary embodiment, means forlowering an expansion device out of an end of the tubular memberincludes means for lowering the expansion device out of the end of thetubular member; and means for adjusting the size of the expansiondevice. In an exemplary embodiment, the adjustable expansion device isadjustable to a plurality of sizes. In an exemplary embodiment, theexpansion device comprises a plurality of adjustable expansion devices.In an exemplary embodiment, at least one of the adjustable expansiondevices is adjustable to a plurality of sizes. In an exemplaryembodiment, means for pulling the expansion device through the end ofthe tubular member includes means for gripping the tubular member; andmeans for pulling an expansion device through an end of the tubularmember. In an exemplary embodiment, means for gripping the tubularmember includes means for permitting axial displacement of the tubularmember in a first direction; and means for not permitting axialdisplacement of the tubular member in a second direction. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member includes means for pulling the expansiondevice through the end of the tubular member using an actuator. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member includes means for pulling the expansiondevice through the end of the tubular member using fluid pressure. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member using fluid pressure includes means forpressurizing an annulus within the tubular member above the expansiondevice. In an exemplary embodiment, means for radially expanding andplastically deforming a portion of the tubular member above the bellsection includes means for fluidicly sealing an end of the tubularmember; and means for pulling the expansion device through the tubularmember. In an exemplary embodiment, the expansion device is adjustable.In an exemplary embodiment, the expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of adjustable expansion devices. In an exemplaryembodiment, at least one of the adjustable expansion devices isadjustable to a plurality of sizes. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberincludes means for gripping the tubular member; and means for pulling anexpansion device through an end of the tubular member. In an exemplaryembodiment, means for gripping the tubular member includes means forpermitting axial displacement of the tubular member in a firstdirection; and means for not permitting axial displacement of thetubular member in a second direction. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberincludes means for pulling the expansion device through the end of thetubular member using an actuator. In an exemplary embodiment, means forpulling the expansion device through the end of the tubular memberincludes means for pulling the expansion device through the end of thetubular member using fluid pressure. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberusing fluid pressure includes means for pressurizing an annulus withinthe tubular member above the expansion device. In an exemplaryembodiment, means for radially expanding and plastically deforming aportion of the tubular member above the bell section includes means foroverlapping the portion of the tubular member above the bell sectionwith an end of a preexisting tubular member; and means for pulling anexpansion device through the overlapping portions of the tubular memberand the preexisting tubular member. In an exemplary embodiment, theexpansion device is adjustable. In an exemplary embodiment, theexpansion device is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of adjustableexpansion devices. In an exemplary embodiment, at least one of theadjustable expansion devices is adjustable to a plurality of sizes. Inan exemplary embodiment, means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member includes means for gripping the tubular member; and meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member. In an exemplaryembodiment, means for gripping the tubular member includes means forpermitting axial displacement of the tubular member in a firstdirection; and means for not permitting axial displacement of thetubular member in a second direction. In an exemplary embodiment, meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member includes means forpulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member using an actuator. Inan exemplary embodiment, means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member includes means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member using fluid pressure. In an exemplary embodiment, meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member using fluid pressureincludes means for pressurizing an annulus within the tubular memberabove the expansion device. In an exemplary embodiment, the systemfurther includes means for cutting an end of the portion of the tubularmember that overlaps with the preexisting tubular member. In anexemplary embodiment, the system further includes means for removing thecut off end of the expandable tubular member from the preexistingstructure. In an exemplary embodiment, the system further includes meansfor injecting a hardenable fluidic sealing material into an annulusbetween the expandable tubular member and the preexisting structure. Inan exemplary embodiment, the system further includes means for cuttingoff an end of the expandable tubular member. In an exemplary embodiment,the system further includes means for removing the cut off end of theexpandable tubular member from the preexisting structure.

A system of radially expanding and plastically deforming a tubularmember has been described that includes a support member; and means forapplying internal pressure to the inside surface of the tubular memberat a plurality of discrete location separated from one another coupledto the support member.

A method of cutting a tubular member has been described that includespositioning a plurality of cutting elements within the tubular member;and bringing the cutting elements into engagement with the tubularmember. In an exemplary embodiment, the cutting elements include a firstgroup of cutting elements; and a second group of cutting elements;wherein the first group of cutting elements are interleaved with thesecond group of cutting elements. In an exemplary embodiment, bringingthe cutting elements into engagement with the tubular member includesbringing the cutting elements into axial alignment. In an exemplaryembodiment, bringing the cutting elements into engagement with thetubular member further includes pivoting the cutting elements. In anexemplary embodiment, bringing the cutting elements into engagement withthe tubular member further includes translating the cutting elements. Inan exemplary embodiment, bringing the cutting elements into engagementwith the tubular member further includes pivoting the cutting elements;and translating the cutting elements. In an exemplary embodiment,bringing the cutting elements into engagement with the tubular memberincludes rotating the cutting elements about a common axis. In anexemplary embodiment, bringing the cutting elements into engagement withthe tubular member includes pivoting the cutting elements aboutcorresponding axes; translating the cutting elements; and rotating thecutting elements about a common axis. In an exemplary embodiment, themethod further includes preventing the cutting elements from coming intoengagement with the tubular member if the inside diameter of the tubularmember is less than a predetermined value. In an exemplary embodiment,preventing the cutting elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value includes sensing the inside diameter of thetubular member.

A method of gripping a tubular member has been described that includespositioning a plurality of gripping elements within the tubular member;bringing the gripping elements into engagement with the tubular member.In an exemplary embodiment, bringing the gripping elements intoengagement with the tubular member includes displacing the grippingelements in an axial direction; and displacing the gripping elements ina radial direction. In an exemplary embodiment, the method furtherincludes biasing the gripping elements against engagement with thetubular member.

A method of operating an actuator has been described that includespressurizing a plurality of pressure chamber. In an exemplaryembodiment, the method further includes transmitting torsional loads.

A method of injecting a hardenable fluidic sealing material into anannulus between a tubular member and a preexisting structure has beendescribed that includes positioning the tubular member into thepreexisting structure; sealing off an end of the tubular member;operating a valve within the end of the tubular member; and injecting ahardenable fluidic sealing material through the valve into the annulusbetween the tubular member and the preexisting structure.

A system for cutting a tubular member has been described that includesmeans for positioning a plurality of cutting elements within the tubularmember; and means for bringing the cutting elements into engagement withthe tubular member. In an exemplary embodiment, the cutting elementsinclude a first group of cutting elements; and a second group of cuttingelements; wherein the first group of cutting elements are interleavedwith the second group of cutting elements. In an exemplary embodiment,means for bringing the cutting elements into engagement with the tubularmember includes means for bringing the cutting elements into axialalignment. In an exemplary embodiment, means for bringing the cuttingelements into engagement with the tubular member further includes meansfor pivoting the cutting elements. In an exemplary embodiment, means forbringing the cutting elements into engagement with the tubular memberfurther includes means for translating the cutting elements. In anexemplary embodiment, means for bringing the cutting elements intoengagement with the tubular member further includes means for pivotingthe cutting elements; and means for translating the cutting elements. Inan exemplary embodiment, means for bringing the cutting elements intoengagement with the tubular member includes means for rotating thecutting elements about a common axis. In an exemplary embodiment, meansfor bringing the cutting elements into engagement with the tubularmember includes means for pivoting the cutting elements aboutcorresponding axes; means for translating the cutting elements; andmeans for rotating the cutting elements about a common axis. In anexemplary embodiment, the system further includes means for preventingthe cutting elements from coming into engagement with the tubular memberif the inside diameter of the tubular member is less than apredetermined value. In an exemplary embodiment, means for preventingthe cutting elements from coming into engagement with the tubular memberif the inside diameter of the tubular member is less than apredetermined value includes means for sensing the inside diameter ofthe tubular member.

A system for gripping a tubular member has been described that includesmeans for positioning a plurality of gripping elements within thetubular member; and means for bringing the gripping elements intoengagement with the tubular member. In an exemplary embodiment, meansfor bringing the gripping elements into engagement with the tubularmember includes means for displacing the gripping elements in an axialdirection; and means for displacing the gripping elements in a radialdirection. In an exemplary embodiment, the system further includes meansfor biasing the gripping elements against engagement with the tubularmember.

An actuator system has been described that includes a support member;and means for pressurizing a plurality of pressure chambers coupled tothe support member. In an exemplary embodiment, the system furtherincludes means for transmitting torsional loads.

A system for injecting a hardenable fluidic sealing material into anannulus between a tubular member and a preexisting structure has beendescribed that includes means for positioning the tubular member intothe preexisting structure; means for sealing off an end of the tubularmember; means for operating a valve within the end of the tubularmember; and means for injecting a hardenable fluidic sealing materialthrough the valve into the annulus between the tubular member and thepreexisting structure.

A method of engaging a tubular member has been described that includespositioning a plurality of elements within the tubular member; andbringing the elements into engagement with the tubular member. In anexemplary embodiment, the elements include a first group of elements;and a second group of elements; wherein the first group of elements areinterleaved with the second group of elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember includes bringing the elements into axial alignment. In anexemplary embodiment, bringing the elements into engagement with thetubular member further includes pivoting the elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember further includes translating the elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember further includes pivoting the elements; and translating theelements. In an exemplary embodiment, bringing the elements intoengagement with the tubular member includes rotating the elements abouta common axis. In an exemplary embodiment, bringing the elements intoengagement with the tubular member includes pivoting the elements aboutcorresponding axes; translating the elements; and rotating the elementsabout a common axis. In an exemplary embodiment, the method furtherincludes preventing the elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value. In an exemplary embodiment, preventing theelements from coming into engagement with the tubular member if theinside diameter of the tubular member is less than a predetermined valueincludes sensing the inside diameter of the tubular member.

A system for engaging a tubular member has been described that includesmeans for positioning a plurality of elements within the tubular member;and means for bringing the elements into engagement with the tubularmember. In an exemplary embodiment, the elements include a first groupof elements; and a second group of elements; wherein the first group ofelements are interleaved with the second group of elements. In anexemplary embodiment, means for bringing the elements into engagementwith the tubular member includes means for bringing the elements intoaxial alignment. In an exemplary embodiment, means for bringing theelements into engagement with the tubular member further includes meansfor pivoting the elements. In an exemplary embodiment, means forbringing the elements into engagement with the tubular member furtherincludes means for translating the elements. In an exemplary embodiment,means for bringing the elements into engagement with the tubular memberfurther includes means for pivoting the elements; and means fortranslating the elements. In an exemplary embodiment, means for bringingthe elements into engagement with the tubular member includes means forrotating the elements about a common axis. In an exemplary embodiment,means for bringing the elements into engagement with the tubular memberincludes means for pivoting the elements about corresponding axes; meansfor translating the elements; and means for rotating the elements abouta common axis. In an exemplary embodiment, the system further includesmeans for preventing the elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value. In an exemplary embodiment, means for preventingthe elements from coming into engagement with the tubular member if theinside diameter of the tubular member is less than a predetermined valueincludes means for sensing the inside diameter of the tubular member.

A locking device for locking a tubular member to a support member hasbeen described that includes a plurality of circumferentially spacedapart locking elements coupled to the support member for engaging aninterior surface of the tubular member; a plurality of spring elementscoupled to the support member for biasing corresponding locking elementsout of engagement with the interior surface of the tubular member; areleasable retaining element releasably coupled to the support memberfor releasably retaining the locking elements in engagement with theinterior surface of the tubular member; an actuator coupled to thesupport member for controllably displacing the retaining elementrelative to the locking elements; and a sensor coupled to the supportmember for sensing an operating condition within the tubular member forcontrollably displacing the retaining element relative to the lockingelements.

A method of locking a tubular member to a support member has beendescribed that includes engaging the interior surface of the tubularmember at a plurality of circumferentially spaced apart locations usingone or more engagement members; and disengaging the engagement membersfrom the interior surface of the tubular member if an operatingcondition within the tubular member exceeds a predetermined amount;wherein the engagement members are biased out of engagement with thetubular member.

A system for locking a tubular member to a support member has beendescribed that includes means for engaging the interior surface of thetubular member at a plurality of circumferentially spaced apartlocations using one or more engagement members; and means fordisengaging the engagement members from the interior surface of thetubular member if an operating condition within the tubular memberexceeds a predetermined amount; wherein the engagement members arebiased out of engagement with the tubular member.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments. Inaddition, one or more of the elements and teachings of the variousillustrative embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. An apparatus for radially expanding and plastically deforming anexpandable tubular member, comprising: a support member; a cuttingdevice for cutting the tubular member coupled to the support member; anexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a locking device forlocking the position of the tubular member relative to the supportmember; and an actuator for displacing the expansion device relative tothe support member; wherein the actuator comprises: a first actuator forpulling the expansion device; and a second actuator for pushing theexpansion device.
 2. An apparatus for radially expanding and plasticallydeforming an expandable tubular member, comprising: a support member; anexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a sealing assembly forsealing an annulus defined between the support member and the tubularmember; a locking device for locking the position of the tubular memberrelative to the support member; and an actuator for displacing theexpansion device relative to the support member; wherein the actuatorcomprises: a first actuator for pulling the expansion device; and asecond actuator for pushing the expansion device.
 3. An apparatus forradially expanding and plastically deforming an expandable tubularmember, comprising: a support member; a first expansion device forradially expanding and plastically deforming the tubular member coupledto the support member; a second expansion device for radially expandingand plastically deforming the tubular member coupled to the supportmember; a locking device for locking the position of the tubular memberrelative to the support member; and an actuator for displacing theexpansion device relative to the support member; wherein the actuatorcomprises: a first actuator for pulling the expansion device; and asecond actuator for pushing the expansion device.
 4. An apparatus forradially expanding and plastically deforming an expandable tubularmember, comprising: a support member; an expansion device for radiallyexpanding and plastically deforming the tubular member coupled to thesupport member; a packer coupled to the support member; a locking devicefor locking the position of the tubular member relative to the supportmember; and an actuator for displacing the expansion device relative tothe support member; wherein the actuator comprises: a first actuator forpulling the expansion device; and a second actuator for pushing theexpansion device.
 5. A method of radially expanding and plasticallydeforming a tubular member, comprising: positioning the tubular memberwithin a preexisting structure; radially expanding and plasticallydeforming a lower portion of the tubular member to form a bell section;radially expanding and plastically deforming a portion of the tubularmember above the bell section; wherein positioning the tubular memberwithin a preexisting structure comprises locking the tubular member toan expansion device; and wherein the radially expanding and plasticallydeforming the tubular member comprises pulling an expansion devicethrough the tubular member with a first actuator and pushing theexpansion device through the tubular member with a second actuator. 6.The apparatus of claim 1, wherein the locking device comprises: ahousing defining a plurality of circumferentially spaced apart openings;a plurality of circumferentially spaced apart locking elements coupledto the housing that extend into corresponding openings of the housingfor engaging an interior surface of the expandable tubular member; and aplurality of spring elements coupled to the housing for biasingcorresponding locking elements out of engagement with the interiorsurface of the expandable tubular member.
 7. The apparatus of claim 6,wherein the locking device further comprises: a fluid powered actuatorcoupled to the housing for displacing the locking element retainerrelative to the locking elements.
 8. The apparatus of claim 6, whereinthe locking device further comprises: a pressure sensor coupled to thelocking element retainer for displacing the locking element retainerrelative to the locking elements if a sensed operating condition exceedsa predetermined value.
 9. The apparatus of claim 1, wherein at least oneof the first and second actuators comprise: a locking device for lockingthe position of the tubular member relative to the support member. 10.The apparatus of claim 9, wherein the locking device comprises: ahousing defining a plurality of circumferentially spaced apart openings;a plurality of circumferentially spaced apart locking elements coupledto the housing that extend into corresponding openings of the housingfor engaging an interior surface of the expandable tubular member; and aplurality of spring elements coupled to the housing for biasingcorresponding locking elements out of engagement with the interiorsurface of the expandable tubular member.
 11. The apparatus of claim 10,wherein the locking device further comprises: a fluid powered actuatorcoupled to the housing for displacing the locking element retainerrelative to the locking elements.
 12. The apparatus of claim 10, whereinthe locking device further comprises: a pressure sensor coupled to thelocking element retainer for displacing the locking element retainerrelative to the locking elements if a sensed operating condition exceedsa predetermined value.
 13. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;an actuator coupled to the support member for displacing the expansiondevice relative to the support member; and a locking device for lockingthe position of the tubular member relative to the support membercomprising one or more locking elements for engaging an interior surfaceof the expandable tubular member; wherein the actuator comprises: alocking device assembly for locking the position of the tubular memberrelative to the support member; wherein the locking device assemblycomprises: one or more locking elements for engaging an interior surfaceof the expandable tubular member; and one or more spring elements forbiasing corresponding locking elements out of engagement with theinterior surface of the expandable tubular member.
 14. The apparatus ofclaim 13, wherein the locking device assembly further comprises: a fluidpowered actuator for displacing a locking element retainer relative tothe locking elements.
 15. The apparatus of claim 13, wherein the lockingdevice assembly further comprises: a pressure sensor for displacing thelocking element retainer relative to the locking elements if a sensedoperating condition exceeds a predetermined value.
 16. The apparatus ofclaim 13, wherein the locking device assembly comprises: a housingdefining a plurality of circumferentially spaced apart openings; aplurality of circumferentially spaced apart locking elements coupled tothe housing that extend into corresponding openings of the housing forengaging an interior surface of the expandable tubular member; and aplurality of spring elements coupled to the housing for biasingcorresponding locking elements out of engagement with the interiorsurface of the expandable tubular member.
 17. The apparatus of claim 16,wherein the locking device assembly further comprises: a fluid poweredactuator coupled to the housing for displacing a locking elementretainer relative to the locking elements.
 18. The apparatus of claim16, wherein the locking device assembly further comprises: a pressuresensor coupled to the locking element retainer for displacing thelocking element retainer relative to the locking elements if a sensedoperating condition exceeds a predetermined value.
 19. An apparatus forradially expanding and plastically deforming an expandable tubularmember, comprising: a support member; an expansion device for radiallyexpanding and plastically deforming the tubular member coupled to thesupport member; an actuator coupled to the support member for displacingthe expansion device relative to the support member; and a lockingdevice for locking the position of the tubular member relative to thesupport member comprising one or more locking elements for engaging aninterior surface of the expandable tubular member; wherein the lockingdevice comprises: a housing defining a plurality of circumferentiallyspaced apart openings; a plurality of circumferentially spaced apartlocking elements coupled to the housing that extend into correspondingopenings of the housing for engaging an interior surface of theexpandable tubular member; and a plurality of spring elements coupled tothe housing for biasing corresponding locking elements out of engagementwith the interior surface of the expandable tubular member.
 20. Theapparatus of claim 19, wherein the locking device further comprises: afluid powered actuator coupled to the housing for displacing the lockingelement retainer relative to the locking elements.
 21. The apparatus ofclaim 19, wherein the locking device further comprises: a pressuresensor coupled to the locking element retainer for displacing thelocking element retainer relative to the locking elements if a sensedoperating condition exceeds a predetermined value.
 22. The apparatus ofclaim 2, wherein the locking device comprises: a housing defining aplurality of circumferentially spaced apart openings; a plurality ofcircumferentially spaced apart locking elements coupled to the housingthat extend into corresponding openings of the housing for engaging aninterior surface of the expandable tubular member; and a plurality ofspring elements coupled to the housing for biasing corresponding lockingelements out of engagement with the interior surface of the expandabletubular member.
 23. The apparatus of claim 22, wherein the lockingdevice further comprises: a fluid powered actuator coupled to thehousing for displacing the locking element retainer relative to thelocking elements.
 24. The apparatus of claim 22, wherein the lockingdevice further comprises: a pressure sensor coupled to the lockingelement retainer for displacing the locking element retainer relative tothe locking elements if a sensed operating condition exceeds apredetermined value.
 25. The apparatus of claim 2, wherein at least oneof the first and second actuators comprise: a locking device for lockingthe position of the tubular member relative to the support member;wherein the locking device comprises: one or more locking elements forengaging an interior surface of the expandable tubular member; and oneor more spring elements for biasing corresponding locking elements outof engagement with the interior surface of the expandable tubularmember.
 26. The apparatus of claim 25, wherein the locking devicefurther comprises: a fluid powered actuator for displacing the lockingelement retainer relative to the locking elements.
 27. The apparatus ofclaim 25, wherein the locking device further comprises: a pressuresensor for displacing the locking element retainer relative to thelocking elements if a sensed operating condition exceeds a predeterminedvalue.
 28. The apparatus of claim 25, wherein the locking devicecomprises: a housing defining a plurality of circumferentially spacedapart openings; a plurality of circumferentially spaced apart lockingelements coupled to the housing that extend into corresponding openingsof the housing for engaging an interior surface of the expandabletubular member; and a plurality of spring elements coupled to thehousing for biasing corresponding locking elements out of engagementwith the interior surface of the expandable tubular member.
 29. Theapparatus of claim 28, wherein the locking device further comprises: afluid powered actuator coupled to the housing for displacing the lockingelement retainer relative to the locking elements.
 30. The apparatus ofclaim 28, wherein the locking device further comprises: a pressuresensor coupled to the locking element retainer for displacing thelocking element retainer relative to the locking elements if a sensedoperating condition exceeds a predetermined value.
 31. The apparatus ofclaim 3, wherein the locking device comprises: a housing defining aplurality of circumferentially spaced apart openings; a plurality ofcircumferentially spaced apart locking elements coupled to the housingthat extend into corresponding openings of the housing for engaging aninterior surface of the expandable tubular member; and a plurality ofspring elements coupled to the housing for biasing corresponding lockingelements out of engagement with the interior surface of the expandabletubular member.
 32. The apparatus of claim 31, wherein the lockingdevice further comprises: a fluid powered actuator coupled to thehousing for displacing the locking element retainer relative to thelocking elements.
 33. The apparatus of claim 31, wherein the lockingdevice further comprises: a pressure sensor coupled to the lockingelement retainer for displacing the locking element retainer relative tothe locking elements if a sensed operating condition exceeds apredetermined value.
 34. The apparatus of claim 3, wherein at least oneof the first and second actuators comprise: a locking device for lockingthe position of the tubular member relative to the support member;wherein the locking device comprises: one or more locking elements forengaging an interior surface of the expandable tubular member; and oneor more spring elements for biasing corresponding locking elements outof engagement with the interior surface of the expandable tubularmember.
 35. The apparatus of claim 34, wherein the locking devicefurther comprises: a fluid powered actuator for, displacing the lockingelement retainer relative to the locking elements.
 36. The apparatus ofclaim 34, wherein the locking device further comprises: a pressuresensor for displacing the locking element retainer relative to thelocking elements if a sensed operating condition exceeds a predeterminedvalue.
 37. The apparatus of claim 34, wherein the locking devicecomprises: a housing defining a plurality of circumferentially spacedapart openings; a plurality of circumferentially spaced apart lockingelements coupled to the housing that extend into corresponding openingsof the housing for engaging an interior surface of the expandabletubular member; and a plurality of spring elements coupled to thehousing for biasing corresponding locking elements out of engagementwith the interior surface of the expandable tubular member.
 38. Theapparatus of claim 37, wherein the locking device further comprises: afluid powered actuator coupled to the housing for displacing the lockingelement retainer relative to the locking elements.
 39. The apparatus ofclaim 37, wherein the locking device further comprises: a pressuresensor coupled to the locking element retainer for displacing thelocking element retainer relative to the locking elements if a sensedoperating condition exceeds a predetermined value.
 40. The apparatus ofclaim 4, wherein the locking device comprises: one or more lockingelements for engaging an interior surface of the expandable tubularmember; and one or more spring elements for biasing correspondinglocking elements out of engagement with the interior surface of theexpandable tubular member.
 41. The apparatus of claim 40, wherein thelocking device further comprises: a fluid powered actuator fordisplacing the locking element retainer relative to the lockingelements.
 42. The apparatus of claim 40, wherein the locking devicefurther comprises: a pressure sensor for displacing the locking elementretainer relative to the locking elements if a sensed operatingcondition exceeds a predetermined value.
 43. The apparatus of claim 4,wherein the locking device comprises: a housing defining a plurality ofcircumferentially spaced apart openings; a plurality ofcircumferentially spaced apart locking elements coupled to the housingthat extend into corresponding openings of the housing for engaging aninterior surface of the expandable tubular member; and a plurality ofspring elements coupled to the housing for biasing corresponding lockingelements out of engagement with the interior surface of the expandabletubular member.
 44. The apparatus of claim 43, wherein the lockingdevice further comprises: a fluid powered actuator coupled to thehousing for displacing the locking element retainer relative to thelocking elements.
 45. The apparatus of claim 43, wherein the lockingdevice further comprises: a pressure sensor coupled to the lockingelement retainer for displacing the locking element retainer relative tothe locking elements if a sensed operating condition exceeds apredetermined value.
 46. The apparatus of claim 4, wherein at least oneof the first and second actuators comprise: a locking device for lockingthe position of the tubular member relative to the support member;wherein the locking device comprises: one or more locking elements forengaging an interior surface of the expandable tubular member; and oneor more spring elements for biasing corresponding locking elements outof engagement with the interior surface of the expandable tubularmember.
 47. The apparatus of claim 46, wherein the locking devicefurther comprises: a fluid powered actuator for displacing the lockingelement retainer relative to the locking elements.
 48. The apparatus ofclaim 46, wherein the locking device further comprises: a pressuresensor for displacing the locking element retainer relative to thelocking elements if a sensed operating condition exceeds a predeterminedvalue.
 49. The apparatus of claim 46, wherein the locking devicecomprises: a housing defining a plurality of circumferentially spacedapart openings; a plurality of circumferentially spaced apart lockingelements coupled to the housing that extend into corresponding openingsof the housing for engaging an interior surface of the expandabletubular member; and a plurality of spring elements coupled to thehousing for biasing corresponding locking elements out of engagementwith the interior surface of the expandable tubular member.
 50. Theapparatus of claim 49, wherein the locking device further comprises: apressure sensor coupled to the locking element retainer for displacingthe locking element retainer relative to the locking elements if asensed operating condition exceeds a predetermined value.
 51. The methodof claim 5, wherein locking the tubular member to an expansion devicecomprises: locking the position of the tubular member relative to asupport member.
 52. The method of claim 51, wherein locking the positionof the tubular member relative to a support member comprises: engagingthe interior surface of the tubular member at a plurality ofcircumferentially spaced apart locations.
 53. The method of claim 52,wherein engaging the interior surface of the tubular member at aplurality of circumferentially spaced apart locations comprises:engaging the interior surface of the tubular member at a plurality ofcircumferentially spaced apart locations using one or more engagementmembers.
 54. The method of claim 53, wherein the engagement members arebiased out of engagement with the tubular member.
 55. The method ofclaim 51, wherein locking the position of the tubular member relative toa support member comprises: unlocking the position of the tubular memberrelative to the support member if an operating condition exceeds apredetermined amount.
 56. The method of claim 55, wherein locking theposition of the tubular member relative to a support member comprises:unlocking the position of the tubular member relative to the supportmember if an operating condition within the tubular member exceeds apredetermined amount.
 57. The method of claim 53, wherein locking theposition of the tubular member relative to a support member comprises:releasing the engagement members from engagement with the tubular memberrelative to the support member if an operating condition exceeds apredetermined amount.
 58. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; a cutting device for cutting the tubular member coupledto the support member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;and a gripping device for gripping the tubular member coupled to thesupport member.
 59. The apparatus of claim 58, wherein the grippingdevice comprises a plurality of movable gripping elements.
 60. Theapparatus of claim 59, wherein the gripping elements are moveable in aradial direction relative to the support member.
 61. The apparatus ofclaim 59, wherein the gripping elements are moveable in an axialdirection relative to the support member.
 62. The apparatus of claim 59,wherein the gripping elements are moveable in a radial and an axialdirection relative to the support member.
 63. The apparatus of claim 59,wherein the gripping elements are moveable from a first position to asecond position; wherein in the first position, the gripping elements donot engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial and an axial direction relative to the supportmember.
 64. The apparatus of claim 59, wherein the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial directionrelative to the support member.
 65. The apparatus of claim 59, whereinthe gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in an axial direction relative to the support member.
 66. Theapparatus of claim 59, wherein, if the tubular member is displaced in afirst axial direction, the gripping device grips the tubular member; andwherein, if the tubular member is displaced in a second axial direction,the gripping device does not grip the tubular member.
 67. The apparatusof claim 59, wherein the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, the gripping elements are biased to remain in the firstposition.
 68. The apparatus of claim 59, wherein the gripping devicefurther comprises: an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator.
 69. An apparatus forradially expanding and plastically deforming an expandable tubularmember, comprising: a support member; a cutting device for cutting thetubular member coupled to the support member; an expansion device forradially expanding and plastically deforming the tubular member coupledto the support member; a sealing device for sealing an interface withthe tubular member coupled to the support member; wherein the sealingdevice seals an annulus defines between the support member and thetubular member; and an actuator for displacing the expansion devicerelative to the support member, wherein the actuator comprises: a firstactuator for pulling the expansion device; and a second actuator forpushing the expansion device.
 70. An apparatus for radially expandingand plastically deforming an expandable tubular member, comprising: asupport member; a cutting device for cutting the tubular member coupledto the support member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;a locking device for locking the position of the tubular member relativeto the support member; and an actuator for displacing the expansiondevice relative to the support member, wherein the actuator comprises: afirst actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device.
 71. An apparatus for radiallyexpanding and plastically deforming an expandable tubular member,comprising: a support member; a cutting device for cutting the tubularmember coupled to the support member; an expansion device for radiallyexpanding and plastically deforming the tubular member coupled to thesupport member; and a packer assembly coupled to the support member,wherein the packer assembly comprises: a packer; and a packer controldevice for controlling the operation of the packer coupled to thesupport member.
 72. The apparatus of claim 71, wherein the packercomprises: a support member defining a passage; a shoe comprising afloat valve coupled to an end of the support member; one or morecompressible packer elements movably coupled to the support member; anda sliding sleeve valve movably positioned within the passage of thesupport member.
 73. The apparatus of claim 71, wherein the packercontrol device comprises: a support member; one or more drag blocksreleasably coupled to the support member; and a stinger coupled to thesupport member for engaging the packer.
 74. The apparatus of claim 71,wherein the packer comprises: a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device comprises: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve.
 75. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; a cutting device for cutting the tubular member coupledto the support member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;and an actuator for displacing the expansion device relative to thesupport member, wherein the actuator comprises: a first actuator forpulling the expansion device; and a second actuator for pushing theexpansion device.
 76. The apparatus of claim 75, wherein at least one ofthe first actuator and the second actuator comprises means fortransferring torsional loads between the support member and theexpansion device.
 77. The apparatus of claim 75, wherein at least one ofthe first actuator and the second actuator comprises a plurality ofpistons positioned within corresponding piston chambers.
 78. Anapparatus for radially expanding and plastically deforming an expandabletubular member, comprising: a support member; a cutting device forcutting the tubular member coupled to the support member; an expansiondevice for radially expanding and plastically deforming the tubularmember coupled to the support member; wherein the cutting devicecomprises: a support member; and a plurality of movable cutting elementscoupled to the support member; an actuator coupled to the support memberfor moving the cutting elements between a first position and a secondposition; wherein in the first position, the cutting elements do notengage the tubular member; and wherein in the second position, thecutting elements engage the tubular member; and a sensor coupled to thesupport member for sensing the internal diameter of the tubular member.79. The apparatus of claim 78, wherein the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. 80.The apparatus of claim 78, wherein the cutting elements comprise: afirst set of cutting elements; and a second set of cutting elements;wherein the first set of cutting elements are interleaved with thesecond set of cutting elements.
 81. The apparatus of claim 80, whereinin the first position, the first set of cutting elements are not axiallyaligned with the second set of cutting elements.
 82. The apparatus ofclaim 80, wherein in the second position, the first set of cuttingelements are axially aligned with the second set of cutting elements.83. An apparatus for radially expanding and plastically deforming anexpandable tubular member, comprising: a support member; a cuttingdevice for cutting the tubular member coupled to the support member; anexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; wherein the expansiondevice comprises: a support member; and a plurality of movable expansionelements coupled to the support member; and an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. 84.The apparatus of claim 83, further comprising: a sensor coupled to thesupport member for sensing the internal diameter of the tubular member.85. The apparatus of claim 84, wherein the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. 86.The apparatus of claim 83, wherein the expansion elements comprise: afirst set of expansion elements; and a second set of expansion elements;wherein the first set of expansion elements are interleaved with thesecond set of expansion elements.
 87. The apparatus of claim 86, whereinin the first position, the first set of expansion elements are notaxially aligned with the second set of expansion elements.
 88. Theapparatus of claim 86, wherein in the second position, the first set ofexpansion elements are axially aligned with the second set of expansionelements.
 89. The apparatus of claim 75, wherein the expansion devicecomprises an adjustable expansion device.
 90. The apparatus of claim 75,wherein the expansion device comprises a plurality of expansion devices.91. The apparatus of claim 90, wherein at least one of the expansiondevices comprises an adjustable expansion device.
 92. The apparatus ofclaim 91, wherein the adjustable expansion device comprises: a supportmember; and a plurality of movable expansion elements coupled to thesupport member.
 93. The apparatus of claim 92, further comprising: anactuator coupled to the support member for moving the expansion elementsbetween a first position and a second position; wherein in the firstposition, the expansion elements do not engage the tubular member; andwherein in the second position, the expansion elements engage thetubular member.
 94. The apparatus of claim 93, further comprising: asensor coupled to the support member for sensing the internal diameterof the tubular member.
 95. The apparatus of claim 94, wherein the sensorprevents the expansion elements from being moved to the second positionif the internal diameter of the tubular member is less than apredetermined value.
 96. The apparatus of claim 93, wherein theexpansion elements comprise: a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. 97.The apparatus of claim 96, wherein in the first position, the first setof expansion elements are not axially aligned with the second set ofexpansion elements.
 98. The apparatus of claim 96, wherein in the secondposition, the first set of expansion elements are axially aligned withthe second set of expansion elements.
 99. An apparatus for radiallyexpanding and plastically deforming an expandable tubular member,comprising: a support member; a cutting device for cutting the tubularmember coupled to the support member; an expansion device for radiallyexpanding and plastically deforming the tubular member coupled to thesupport member; and a gripping device for gripping the tubular membercoupled to the support member, wherein the gripping device comprises aplurality of movable gripping elements; wherein the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position.
 100. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;an actuator coupled to the support member for displacing the expansiondevice relative to the support member, wherein the actuator comprises: afirst actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device; and a sealing device for sealing aninterface with the tubular member coupled to the support member; whereinthe sealing device seals an annulus defines between the support memberand the tubular member.
 101. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;an actuator coupled to the support member for displacing the expansiondevice relative to the support member; and a packer assembly coupled tothe support member, wherein the packer assembly comprises: a packer; anda packer control device for controlling the operation of the packercoupled to the support member.
 102. The apparatus of claim 101, whereinthe packer comprises: a support member defining a passage; a shoecomprising a float valve coupled to an end of the support member; one ormore compressible packer elements movably coupled to the support member;and a sliding sleeve valve movably positioned within the passage of thesupport member.
 103. The apparatus of claim 49, wherein the lockingdevice further comprises: a fluid powered actuator coupled to thehousing for displacing the locking element retainer relative to thelocking elements.